E-Bike 36V Service Manual - Chapter Five
connect the cable guide from the bracket on
the left caliper arm.
2. Remove the brake pad nut (F, Figure 8) from
the pad stud .
3. Remove the plain washer (E, Figure 8), the
concave washer (D, Figure 8), and the convex
washer (C, Figure 8) from the pad stud.
4. Remove the brake pad from the caliper arm.
5. Remove the convex (B, Figure 8) and con-
cave washers (A, Figure 8) from the brake
pad. Discard the old pad. Do not mix the
inboard and the outboard parts.
Installation
Brake pads on the E-Bike
®
are not inter-
changeable. The pads are marked left ("L")
and right ("R"). Be sure to install a left pad on
a left caliper arm and a right pad on a right
arm.
1. Find the left ("L") or right ("R") marking on
the new brake pad. Be sure to install the cor-
rect pad onto the caliper arm.
2. Install the inboard concave washer (A,
Figure 8) onto the stud of the new brake pad.
The flat side of the washer must face the brake
pad.
3. Install the inboard convex washer (B, Figure
8) onto the pad stud so the convex side faces
the concave washer.
4. Fit the brake-pad stud through the cutout in
the caliper arm.
5. Slide the convex washer (C, Figure 8) onto
the pad stud so the convex side faces out away
from the caliper arm.
6. Install the concave washer (D, Figure 8) so
the flat side of the washer faces out.
7. Install the plain washer (E, Figure 8).
8. Apply Loctite to the threads of the pad stud,
and install the brake pad nut (F, Figure 8).
Tighten the nut to the torque specification in
Table 4.
9. Align the brake pads as described in this
chapter.
BRAKE PAD ALIGNMENT
Brake efficiency is affected by four parame-
ters: toe, vertical-angle, tangent, and height.
Toe alignment determines how the brake-
pad face sits against the brake surface of the
rim. When properly adjusted, a pad’s trailing
end (the end facing the front) should reach the
rim before the leading end (Figure 9). Vertical
alignment sets the position of the pad’s vertical
Chapter Five
5-4
inner wire; turning the adjuster in
loosens the wire.)
c. When the brake lever is within specifica-
tion, tighten the adjuster locknut.
5. Squeeze the caliper arms together,
and remove the cable guide from the
bracket on the left caliper arm (A, Figure
1). The brake-lever free play is properly
adjusted if the cable guide can be easily
removed from the bracket.
6. If you cannot easily release the cable guide
from the bracket, perform the following:
a. Loosen the locknut and turn the adjust
ing barrel at the brake lever in (clock
wise) one full turn. Try to remove the
cable guide again.
b. If you still cannot release the cable
guide, turn the adjusting barrel in an
additional turn.
c. If the cable guide still does not release,
loosen the pinch bolt (B, Figure 1) and
release 2-3 mm (0.079-0.118 in.) of
inner wire from the pinch mechanism.
d. Repeat the adjusting procedure.
BRAKE PAD
The brake pads in the E-Bike
®
use a thread-
ed-stud/curved-washer system (Figure 8).
Convex and concave washers on each side of
the brake caliper arm control how the pad is
positioned against the wheel.
Removal
NOTE
Do not mix the parts during disassembly. The
convex and concave washers become mated
through use, and they must be reinstalled in
the same position during assembly.
1. Squeeze the caliper arms together, and dis-
FIG.8
A
B
C
D
E
F