Operator`s manual

SECTION 7

MAINTENANCE INFORMATION

7.3.2 BRAKE CALIPER ADJUSTMENT

Adjust the calipers when:

• the brake adjustment nuts are tightened all the way but

the steering lever travel still exceeds 7" or

• the total clearance between the brake pads and the brake

disc exceeds .010".

To adjust the brake calipers:

1. Tighten the lock nut with a 1/2" open end wrench, no

wider than the thickness of the lock nut (Figure 7-21).

As the lock nut is tightened, measure the clearance be-

tween the brake disc and pad as shown in Figure 7-22,

using a .010" feeler gauge. .010" is the correct clearance

between the left brake pad and the brake disc when the

right pad is pressed against the disc.

Figure 7-20. Mechanical brake assemblies

4. Remove the gearshift knob.

5. Remove the 2 firewall retaining bolts with a 3/8" wrench

(refer to Section 1.6)

6. Pull the bottom of the firewall back and lift it out of the

vehicle.

Mechanical brake inspection procedure

With the firewall removed, inspect both brake caliper as-

semblies.

Figure 7-22. Measuring the distance between the brake disc and

brake pad.

To replace the brake pads:

Use an electric drill and 1/4" drill bit to remove the heads of

the rivets holding the old pads to the calipers. Clear the

remainder of the rivets from the calipers and install each

100-56 brake pad set (2 pads) using 8 of 120-09 rivets and a

Figure 7-21. Tightening the lock nut

7.3.3 BRAKE PAD REPLACEMENT

During the inspection of all 4 brake pads, if they are:

• worn to 3 mm (1/8") thickness as shown in Figure 7-22;

• glazed and brake efficiency is affected; or

• contaminated with lubricant and brake performance is

affected;

• they are no longer serviceable and must be replaced.

2. Use another 1/2" open wrench to tighten the outer lock

nut to the inner one.

3. Tighten the adjustment lock nut with a 1/2" wrench so it

is snug but the bolt can still be turned freely with fingers.

4. Adjust the other brake caliper assembly by repeating steps

1 to 3.