Servicing Brakes

The front wheel brake is operated by a hand lever on the right handlebar side, and the rear wheel brake is operated by a foot pedal on the left side of the motorcycle. Both hand lever and foot lever controls are connected to their respective brake shoe operating shafts independently through mechanical linkage. Compressing the front wheel brake hand lever and depressing the rear wheel brake foot lever actuates the operating shaft cam, moving brake shoes against the brake drum. To keep brakes in proper operating condition, it is essential to check adjustment of brakes at regular service intervals of 5000 miles, or sooner, depending on wear of brake linings and drums. See adjustment of brakes and centeringbrake shoes. If brakes do not operate satisfactorily after adjustment of linkage and re-centering brake shoes in drums, disassemble and service brakes and connecting linkage.

ADJUSTING FRONT WHEEL BRAKE (Fig. 2G-8)

When the front wheel brake is properly adjusted, the hand lever will move freely about one-quarter of its full movement before the brake starts to take effect. If adjusted tighter the brake may drag. To adjust brake, loosen lock nut (1) on adjusting sleeve (2) and turn sleeve nut (3) in toward the cable support tube to decrease the free movement of hand lever and tighten the brake. Turn sleeve nut (3) away from the cable support tube to increase the free movement of hand lever and loosen the brake. When free movement of the hand lever is about one-quarter of its full movement, tighten lock nut (1) against adjusting sleeve nut

(3). Rotate the wheel to make sure brake is not too tight and dragging. If brake should drag with correct free movement in hand lever, re-center brake shoes in brake drum as follows:

Loosen, but do not remove, front brake shoe pivot stud (4) and axle nut (5). Spin front wheel. While wheel is turning apply brake and tighten pivot stud

(4) and then axle nut (5). Re check brake for correct adjustment as described above.

ADJUSTING REAR WHEEL BRAKE (Fig. 2G-9)

To adjust rear wheel brake turn adjusting nut (1) to change the effective length of the brake rod (2). The adjusting nut has a notch which fits against the clevis pin in the operating lever (3). Thus, it is locked in place on the rod, but may be turned down or backed off the rod by half turns as required. Set the adjusting nut so that the brake begins to take effect when

1. Adjusting sleeve lock nut

2. Front brake adjusting sleeve

3. Adjusting sleeve nut

4. Brake shoe pivot stud

5. Front wheel axle nut

6. Brake cable

7. Brake cable clevis clamp nut

8. Brake cable clevis clamp

9. Brake cable support tube 10. Brake lever

1. Brake rod adjusting nut

2. Brake rod

3. Operating lever

4. Brake shoe pivot stud nut

5. Rear wheel axle nut

Figure 2G-8. Front Wheel Brake Figure 2G-9. Rear Wheel Brake

Figure 2G-10. Front Wheel Brake - Exploded View

1. Pivot stud screw and washer

2. Operating shaft nut

3. Operating lever

4. Operating shaft

5. Operating shaft washer

6. Shoe pivot stud

7. Brake side plate

8. Brake shoe and lining (2)

Figure following name of part indicates quantity necessary for one complete assembly.

the foot lever is pushed downward about 1-1/4 in. Turn the nut onto the rod to tighten the brake; back it off to loosen the brake. Turn the wheel to be sure the brake is not too tight and dragging. If brake should drag with correct free movement in foot pedal, re-center brake shoes in brake drum as follows:

Loosen but do not remove rear brake pivot stud nut (4) and axle nut (5). Spin rear wheel. While wheel is turning apply brake and tighten pivot stud nut (4) and then the axle nut (5). Re-check brake for correct adjustment, as previously described.

REPLACING FRONT WHEEL BRAKE CABLE (Fig. 2G-8)

If the front wheel brake cable (6) is not free in its housing, is frayed or broken, replace cable. Remove clevis clamp nut (7) and clamp (8). Free cable from clevis and pull from upper end of coil. Install new cable from upper end of housing as positioned on motorcycle, applying a light coat of grease as it is inserted into coil. When reassembling cable ferrule in hand lever anchor pin with side slot, be sure slot is toward inside as shown. Earlier type pin with slotted end should have open end facing downward.

To correctly adjust brake cable turn adjusting sleeve lock nut (1) and adjusting sleeve nut (3) to the top of brake adjusting sleeve (2). Make sure brake cable end is correctly positioned in brake lever slot, control coil ferrule is correctly positioned in hand lever bracket slot, and the brake cable support tube (9) is positioned in the fork slider bracket. Take all slack out of brake cable by pulling at the lower end of cable. With front brake lever (10) in lowest position (brake released), loop cable (6) around clevis and secure in place with clevis clamp (8) and nut (7). Adjust brake as described in "Adjusting Front Wheel Brake."

DISASSEMBLING FRONT WHEEL BRAKE (Fig. 2G-10)

Remove front wheel and brake assembly from motor cycle as described in "Removing and Installing Front Wheel," Section 2C. Remove operating shaft nut (2) and operating lever (3). Lightly tap operating shaft (4) to remove brake shoes (8), springs (9), operating shaft (4), washer (5) and pivot stud (6) as a unit from brake side plate (7). Remove shoes from operating shaft (4) and pivot stud (6).

DISASSEMBLING REAR WHEEL BRAKE (Fig. 2G-11)

Remove rear wheel from motorcycle as described in "Removing and Installing Rear Wheel," Section 2C. Remove rear brake rod adjusting nut (1) and free brake rod (2) from operating lever (3). Remove brake assembly from motorcycle. Remove operating shaft nut and washer (4), operating lever (3), pivot stud nut and lock washer (5) and locating block (6). Lightly tap operating shaft (7) to remove brake shoes (8), springs (9), pivot stud (10), operating shaft (7) and washer (11) as a unit from brake side plate (12). Remove shoes from operating shaft (7) and pivot stud (10).

INSPECTING AND REPAIRING BRAKE (Fig. 2G-10 and 2G-11)

Clean and inspect brake shoes and linings (8) for wear, loose rivets, glazing, or imbedded particles. Brake shoes that are badly worn, cracked or damaged must be replaced. Linings (10 and 13) that are worn down to rivet heads, hard or glazed, impregnated with grease, cracked or damaged, must be replaced. Linings that are only slightly glazed and in apparent good condition may be re-used after being roughened with a medium grade of sandpaper. Also, be sure to roughen braking surface of the brake drum.

If replacement of brake linings is necessary, new linings can be riveted to the old shoes, or, if riveting facilities are not available, brake shoes and linings can be renewed. To reline old shoes remove and discard old rivets and linings. Position new lining on brake shoe and head rivets, working from one end to the other to achieve a tight fit and avoid buckling. If a riveting machine is not available, set rivets with hand tools. After riveting linings to the brake shoes, bevel each end of brake lining as shown in Fig. 2G-12.

Clean all dirt from brake drums (not shown), and examine for scoring, grooving, or excessive wear. Inspect brake operating shaft (4 and 7), pivot stud (6 and 10), and brake side (7 and 12) for excessive wear of shaft bearing surfaces. Recommended repair procedure is replacement of badly worn or damaged parts.

ASSEMBLING FRONT WHEEL BRAKE (Fig. 2G-10)

Assembly is essentially the reverse order of disassembly. Assemble brake shoes (8) on operating-shaft (4) and pivot stud (6) with one spring (9). Secure spring in groove that is nearest brake side plate. Position washer (5). Assemble unit to brake side plate (7). Make sure flat side of pivot stud (6) registers in recess of brake side plate. Install operating lever (3) and nut (2). Attach second spring in place with pliers. Install front wheel and brake assembly as described in "Removing and Installing Front Wheel," Section 2C. Adjust brakes and center brake shoes as described in "Adjusting Front Wheel

Brake."

ASSEMBLING REAR WHEEL BRAKE (Fig. 2G-11)

Assembly is essentially the reverse order of disassembly. Assemble brake shoes (8) on operating shaft (7) and pivot stud (10) with one spring (9). Secure spring in groove nearest brake side plate. Position washer (11) on shaft (7). Assemble unit on brake side plate (12). Install locating block (6), nut and lock washer (5), operating lever (3) and nut and lock washer (4). Attach second spring in place with pliers. Position brake assembly in rear wheel brake drum and install wheel assembly in frame as described in "Removing and Installing Rear Wheel," Section 2C. Insert brake rod (2) through lever (3). Assemble adjusting nut (1) loosely on rod (2). Adjust brakes and center brake shoes as described in "Adjusting Rear Wheel Brake."

1. Brake rod adjusting nut

2. Brake rod

3. Brake operating lever

4. Operating shaft nut and lock washer

5. Pivot stud nut and lock washer

6. Locating block

7. Operating shaft

10. Pivot stud

11. Operating shaft washer

12. Brake side plate

13. Brake lining (2)

14. Cross shaft

15. Rod clevis cotter pin and washer

16. Rod clevis pin

17. Foot lever bolt and nut

18. Foot lever

19. Lever torsion spring

20. Frame brake shaft tube bushing (2)

21. Cross shaft adjusting screw and nut

Figure following name of part indicates quantity necessary for one complete assembly.

Figure 2G-11. Rear Wheel Brake - Exploded View

DISASSEMBLING REAR BRAKE CROSS SHAFT (Fig. 2G-11)

If it is necessary to remove the brake cross shaft

(14) from the motorcycle, proceed as follows:

Disconnect rear chain and remove exhaust pipe and muffler from motorcycle. Free brake rod (2) clevis from cross shaft (14) lever arm, by removing washer and cotter pin (15) and clevis pin (16). Discard pin

(15). Loosen pinch bolt (17), slip foot lever (18) and spring (19) from shaft (14). Remove shaft (14) from frame tube.

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