Polaris EV206PH-B Manuale utente

Electric Bicycle

Technical/Service Manual

Polaris and its vehicle body designs and names are registered trademarks of Polaris Industries Inc. used under license.

Polaris designs, engineers, manufactures and markets snowmobiles, all-terrain vehicles (ATVs), Victory motorcycles and

the Polaris RANGER for recreational and utility use. Information about the complete line of Polaris products, apparel

and vehicle accessories is available from authorized Polaris dealers or anytime from the Polaris homepage at www.

polarisindustries.com.

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TABLE OF CONTENTS

CHAPTER 1 ................................................................................................................................. 1

GENERAL INFORMATION.......................................................................................................... 1

TERMS LEFT AND RIGHT................................................................................................................................ 1

NOTES, CAUTIONS AND WARNINGS ............................................................................................................ 1

TROUBLESHOOTING / DIAGNOSTIC GUIDE................................................................................................ 2

TOOLS ................................................................................................................................................................ 4

SPECIFICATIONS.............................................................................................................................................. 4

TABLE 1: ELECTRICAL SPECIFICATIONS.................................................................................................. 4

TABLE 2: PARTS............................................................................................................................................. 4

GENERAL WARRANTY INFORMATION.......................................................................................................... 6

COMPONENTS TO BECOME FAMILIAR WITH WHICH ARE COVERED UNDER WARRANTY............ 6

BICYCLE OVERVIEW.................................................................................................................................... 6

WARRANTY PROGRAM DETAILS................................................................................................................... 7

MOTOR SYSTEM COMPONENT WARRANTY........................................................................................... 7

NON-ELECTRIC COMPONENT WARRANTY............................................................................................. 7

SERVICING OF PARTS ..................................................................................................................................... 7

CHAPTER 2 ................................................................................................................................. 8

STEERING AND SUSPENSION................................................................................................. 8

HANDLEBAR REPLACEMENT......................................................................................................................... 8

REMOVAL....................................................................................................................................................... 8

INSTALLATION ............................................................................................................................................... 9

HANDLEBAR STEM ......................................................................................................................................... 9

REMOVAL....................................................................................................................................................... 9

INSTALLATION ............................................................................................................................................... 10

FRONT FORK REMOVAL/INSTALLATION....................................................................................................... 11

REMOVAL....................................................................................................................................................... 11

INSTALLATION ............................................................................................................................................... 12

CHAPTER 3 ................................................................................................................................. 13

BRAKES ....................................................................................................................................... 13

BRAKE LEVER REMOVAL/INSTALLATION..................................................................................................... 13

REMOVAL....................................................................................................................................................... 13

INSTALLATION .............................................................................................................................................. 13

BRAKE CABLE INNER WIRE .......................................................................................................................... 14

REMOVAL....................................................................................................................................................... 14

INSTALLATION ............................................................................................................................................... 14

BRAKE CALIPER REMOVAL/INSTALLATION ................................................................................................. 16

BRAKE CALIPER REMOVAL ........................................................................................................................ 16

INSTALLATION ............................................................................................................................................... 16

BRAKE PAD REPLACEMENT........................................................................................................................... 16

BRAKE DISC REMOVAL/INSTALLATION ........................................................................................................ 17

CHAPTER 4 ................................................................................................................................. 18

SHIFTER AND DERAILLEUR..................................................................................................... 18

REMOVAL....................................................................................................................................................... 18

INSTALLATION ............................................................................................................................................... 18

SHIFTER CABLE INNER WIRE REMOVAL/INSTALLATION .......................................................................... 19

REMOVAL....................................................................................................................................................... 19

INSTALLATION ............................................................................................................................................... 20

DERAILLEUR ..................................................................................................................................................... 21

DERAILLEUR LUBRICATION ....................................................................................................................... 21

DERAILLEUR ADJUSTMENT....................................................................................................................... 21

SETTING CABLE TENSION.......................................................................................................................... 22

DERAILLEUR INSTALLATION....................................................................................................................... 22

CHAPTER 5 ................................................................................................................................. 23

CHAIN AND CRANKSET ............................................................................................................ 23

CHAIN................................................................................................................................................................. 23

INSPECTION.................................................................................................................................................. 23

CHECKING CHAIN LENGTH ........................................................................................................................ 23

REMOVAL....................................................................................................................................................... 24

CLEANING...................................................................................................................................................... 24

INSTALLATION ............................................................................................................................................... 24

LUBRICATION ................................................................................................................................................ 25

CRANK ARM ...................................................................................................................................................... 25

REMOVAL....................................................................................................................................................... 25

INSPECTION.................................................................................................................................................. 26

INSTALLATION ............................................................................................................................................... 27

CHAINRING........................................................................................................................................................ 27

REMOVAL....................................................................................................................................................... 27

INSTALLATION ............................................................................................................................................... 27

CHAINRING WOBBLE CHECK......................................................................................................................... 28

PEDAL ............................................................................................................................................................... 28

REMOVAL....................................................................................................................................................... 28

INSTALLATION ............................................................................................................................................... 28

BOTTOM-BRACKET CARTRIDGE................................................................................................................... 29

REMOVAL....................................................................................................................................................... 29

INSTALLATION ............................................................................................................................................... 30

CHAPTER 6 ................................................................................................................................. 31

MOTOR SYSTEM ........................................................................................................................ 31

TROUBLESHOOTING DIAGNOSTIC GUIDE.................................................................................................. 31

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CHAPTER 1

GENERAL INFORMATION

In the pages that follow, EVantage will provide you with detailed instructions on how to service your

customers Electric Bicycles. We will cover both electric and non electric components for the bicycles, how to

service them, and service program procedure.

TERMS LEFT AND RIGHT

The terms left and right in this manual refer to the rider’s point of view when seated on the Polaris®electric

bicycle and facing forward. The right side of the Polaris®electric bicycle is the chain side. The left side is the

brake side.

NOTES, CAUTIONS AND WARNINGS

The terms NOTE, CAUTION and WARNING have speciﬁc meanings in this manual. A NOTE provides addi-

tional information to make a procedure easier or clearer.

A CAUTION emphasizes precautions that must be taken to avoid damage to tools or the Polaris®electric

bicycle. Disregarding a CAUTION could lead to mechanical damage.

A WARNING emphasizes a situation where negligence could lead to injury or death. Take WARNINGS

seriously. Failure to heed a WARNING could result in serious personal injury or death.

CONTROLLER CAP REMOVAL/INSTALLATION......................................................................................... 31

DUO DRIVE MOTOR SERVICE........................................................................................................................ 32

REAR WHEEL MOTOR REMOVAL .............................................................................................................. 32

REAR WHEEL MOTOR INSTALLATION....................................................................................................... 33

SMART CONTROLLER SERVICE.................................................................................................................... 34

SMART CONTROLLER REMOVAL .............................................................................................................. 34

SMART CONTROLLER INSTALLATION ...................................................................................................... 35

PRO-RIDE LITHIUM BATTERY SERVICE ....................................................................................................... 35

IC DASHBOARD SERVICE ............................................................................................................................... 36

IC DASHBOARD REMOVAL.......................................................................................................................... 36

IC DASHBOARD INSTALLATION.................................................................................................................. 36

THROTTLE SERVICE ....................................................................................................................................... 37

THROTTLE REMOVAL .................................................................................................................................. 37

THROTTLE INSTALLATION .......................................................................................................................... 37

ILLUSTRATION INDEX................................................................................................................ 38

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2 3

TROUBLESHOOTING / DIAGNOSTIC GUIDE

Motor sounds like it engages, but does

not move

Listen for clicking inside the motor

when actuated.

Display does not turn ON

Check cable connectors.

Charge battery for at least 4-6 hours.

Check battery voltage with multi-meter.

Replace controller as needed.

Inspect the charger lights are operating

properly.

Inspect both charger ports for damage.

Check battery lead wires and controller

connections.

Display turns ON but motor does not

engage through pedal assist

Check motor connections in controller

area.

Inspect torque sensor for damage or

faulty connection.

With multi-meter, check voltage from

controller lead to motor.

Display turns ON but does not engage

through throttle

Check motor connections in controller

area.

Check cable connections from throttle

for damage.

Inspect torque sensor for damage or

faulty connection.

With multi-meter, check voltage from

controller lead to motor.

Replace throttle as needed .

Display does not turn ON, but motor

engages

Check cable connections in controller

area.

Check cable connections within display

unit.

Replace dash as needed.

Brakes fail to cut motor when engaged

Check wires for damage.

Check controller connections.

Replace brake switch handles as

needed.

Replace controller as needed.

Replace motor as needed.

Motor engages and operates with

abnormal noise

Check connectors and controller.

Check motor, wheel/axle for damage.

Replace controller accordingly.

Replace motor, wheel/ axle.

Motor does not engage and has

abnormal noise

Check connectors and controller.

Check motor, wheel/axle for damage.

Replace controller.

Replace motor, wheel.

Motor wheel wobbles

Check motor/wheel/axles/spokes for

damage. Replace motor, wheel accordingly.

Display malfunction

Check connectors at controller.

Check connectors at display.

Check display and cables for damage.

Replace controller.

Replace display.

Throttle malfunction

Check throttle cable for damage.

Check connectors at controller.

Replace throttle.

Replace controller.

Battery charger malfunction

Check for good quality AC power, and

no extension cord usage.

Replace battery charger.

LED headlight malfunction

Check LED cable for damage. Replace LED.

Battery malfunction

FULL status: battery does not power

up bike.

EMPTY status: battery does not accept

charge.

Battery is frozen: Do not attempt to

recharge a frozen battery.

Check charger.

Replace battery.

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4 5

Item # Ft.-Lb. Special Instructions

Brake caliper mounting

bolt

5-7 40-60 Apply Loctite 242

Brake disc bolt 6.2 55 Apply Loctite 242

Brake lever clamp bolt 3-3.9 26.5-34.7

Chainring bolt 6-8 53-71

Crank arm bolt 35-40 26-30 Apply grease to bolt threads

Derailleur anchor bolt 4.1 36.5

Derailleur mounting bolt 7.9 70

Front fender 3 26.5

Handlebar binder bolt 6 53 Apply grease to bolt threads

Handlebar stem clamp

bolt

12 106

Pedal 3-4.9 26.5-43.4 Apply grease to stud threads

Rear axle nut 60-65 44-48

Rear fender bolt 4 35

Rear fender stay bolt 2 17.7

Seat post clamp bolt 10-12 89-106

Shifter set screw 3-3.9 26.5-34.7

Shock absorber bolt 16-20 12-14.5 Apply Loctite 242

Swingarm bolt 18-22 13-16 Apply Loctite 242

Throttle set screw 3-3.9 26.5-34.7

Torque arm bolt 9-10 80-89

SERIAL NUMBER IDENTIFICATION

The serial ID number is an 8-digit code located either on the front or back of the bicycle headtube. This

number should be referenced when registering warranty or service claims.

TOOLS

The following special tools are needed when servicing the Vector EV200PH:

Tool Part Number

Star shaped wrench set Park TWS-2

Head cup remover Park RT-1

Bearing cup press Park HHP-3

Hex wrench set: 4mm, 5mm, 6mm Park AWS-1

Hex wrench set Park AWS-11C

Hex wrench set: 2mm, 5mm, 3mm Park AWS-3

Fourth-hand cable stretcher Park BT-2

Chain checker Park CC-2C

Chain breaker (screw type) Park CT-3

Crank wrench Park CCW-14R

Cable and housing cutter Park CN-4C

Gearclean brush Park GSC-1

32mm & 36mm head wrench Park HCW-15

Pedal wrench Park PW-3

Spoke wrench (black) Park SW-0

Spoke wrench (red) Park SW-2

Tire lever set Park TL-1C

Freewheel tool Part Tool FR-1

Bottom-bracket-cartridge tool Park Tool BBT-2

SPECIFICATIONS

Table 1: Electrical Speciﬁcations

Component Speciﬁcation

Battery 29.6V

Type Lithium Manganese

Capacity 6Ah (178 watt/hr)

Charger EVantage Smart Battery Charger

Input 120vAC, 60Hz

Output

Table 2: Parts

Item # Ft.-Lb. Special Instructions

Bottom-bracket cartridge

adapter ring

29.4 21.7-28 Apply grease to the threads

Brake caliper anchor bolt 5-7 40-60

Brake caliper CPS bolt 8-10 70-90

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6 7

WARRANTY PROGRAM DETAILS

The warranty program is detailed below. Warranty dating in all cases is set from date of purchase. Bicycle

owner must show proof of date of purchase, and also proof that they are the initial purchaser. Any resale of

the bike voids the warranty.

Motor System Component Warranty

DuoDrive Motor (1 year from date of purchase)

Smart Controller (1 year from date of purchase)

ProRide Lithium Battery (1 year from date of purchase)

IC Dashboard Display (1 year from date of purchase)

Throttle (1 year from date of purchase)

All other motor components (1 year from Date of purchase)

Non-Electric Component Warranty

6 months from date of purchase (excluding tires, tubes, spokes, chain)

SERVICING OF PARTS

When a customer comes in with a customer service request, hopefully they have already contacted EVantage

customer support directly, and we have directed them to you. If they have come in without previously

speaking with our customer service team you can either contact us by phone or submit a service request

form at www.polarisebikes.com/servicerequest . One of our customer service members would be more than

happy to help you diagnose the problem and ﬁnd the accurate solution.

All motor system parts are stocked in our warehouse, and can be made available to you as needed.

All non-motor system parts, are not stocked in warehouse. Please order replacement bicycle parts either from

your local parts distributor, or through our parts distribution network. If ordered directly by you, component

costs can be used as credit towards your next POLARIS electric bicycle purchase, only if the product is still

under warranty.

Labor Costs: Labor can be billed back to EVantage at a hourly rate of $10/hr, with a maximum labor cost of

$40.00 per service project. Labor costs will be credited to your account, and can be deducted from any future

order.

GENERAL WARRANTY INFORMATION

Components To Become Familiar With Which Are Covered Under Warranty

Bicycle Overview

IN-FRAME MODELS (EV206PH-B, EV206PH-S)

REAR RACK MODELS (EV306PH-B, EV306PH-S,

EV316PH-G, EV316PH-L, EV407PH-G, EV407PH-B, EV417PH-W, EV417PH-B

1. DuoDrive Rear Hub Motor

2. In Frame ProRide Lithium-Ion Battery

3. Information Center Dashboard

4. Charging Socket (opposite side)

5. Throttle

6. Smart Controller

7. SRAM x7, 8 Speed Derailleur

8. Dual Disk Brakes

9. Suspension Fork

10.Front Quick Release Axle/Wheel

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8 9

FIGURE 2-3

Installation

1. Install the handlebar by reversing the removal procedures.

a. Make sure the handlebar is centered and properly oriented within the handlebar stem.

b. Apply grease to the handlebar binder bolts (Figure 2-3), and evenly tighten the bolts in a star pattern so

the gap at the top of the clamp is the same as the gap at the bottom. Torque the handlebar binder bolts

to the speciﬁcation in Table 5.

c. Slide the reﬂector, each brake lever, throttle, display, shifter onto their respective handlebar ends.

d. Install handlebar grip onto each handlebar end.

e. Position the throttle, shifter and display relative to its handlebar grip as noted during removal. Tighten

their set-screws and clamp bolts.

f. Slide each brake lever so its bracket seats against the throttle or shifter. Rotate the brake lever to the

position noted during removal, and torque the brake lever clamp bolts to the speciﬁcation in Table 5.

g. Rotate the throttle and shifter so their barrels rest against the brake lever. Torque the throttle set screw

and the shifter clamp bolt to the speciﬁcations in Table 5.

HANDLEBAR STEM

Removal

1. If necessary, remove the handlebar binder bolts (Figure 2-3), and remove the handlebar from the

handlebar stem. Use a bungee cord to suspend the handlebar from the frame.

2. Loosen the handlebar stem bolt from the top of the handlebar stem (A, Figure 2-4). You may remove bolt

and cap.

FIGURE 2-4

C A

CHAPTER 2

STEERING AND SUSPENSION

WARRANTY NOTE: Steering and front suspension fall under “non-electric” component warranty. Applicable

warranty is 6 months from date of purchase. Any service issue resulting from misuse of bicycle is not

covered under this warranty and user shall be responsible for all charges .

HANDLEBAR REPLACEMENT

Removal

1. Note the position of the throttle and the shifter relative to its handlebar grip. If necessary, measure the

gap between each item and its handlebar grip or make a drawing so these components can be reinstalled

with the proper positioning and orientation. Also note the orientation of the handlebar within the handlebar

stem.

2. Remove the left and right handlebar grip.

3. Loosen the throttle set screw (A, Figure 2-1), shifter clamp bolt (A, Figure 2-2), the reﬂector clamp bolt

screw, the clamp bolt on each brake lever (B, Figure 2-2), and display unit set-screw. (B, Figure 2-1)

4. Remove the handlebar binder bolts (Figure 2-3).

5. Lower the handlebar from the handlebar stem.

6. Slide the throttle, shifter, display, brake levers and the reﬂector assembly from the handlebar ends and

remove the handlebar.

FIGURE 2-1

FIGURE 2-2

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10 11

c. With the front wheel off the ground, turn the handlebar from full stop to full stop. The fork should turn

smoothly.

d. Torque the handlebar stem clamp bolts (A, Figure 2-4) to the speciﬁcation in Table 5.

e. Tighten the handlebar stem bolts (B, Figure 2-4) an additional 30 degree (clockwise).

f. With the front wheel off the ground (A, Figure 2-4), again turn the handlebar from full stop to full stop.

The fork should turn smoothly.

FRONT FORK REMOVAL/INSTALLATION

Removal

The front fork is not serviceable. If the fork is damaged, it must be replaced.

1. Remove the handlebar (this chapter).

2. Remove cable holder bolt with 3mm hex wrench (A, Figure 2-8) and release the front brake cable

(B, Figure 2-8) from the holder.

3. Remove the caliper mounting bolts (A, Figure 2-10), and slide the front brake caliper (B, Figure 2-9) from

the brake disc. Suspend the caliper with a bungee cord (A, Figure 2-9).

4. Remove the front wheel.

FIGURE 2-8

FIGURE 2-5

FIGURE 2-6

FIGURE 2-7

3. Loosen the handlebar stem clamp bolts (B, Figure 2-4)

4. Lift the handlebar stem (C, Figure 2-4) from the head tube.

5. If necessary, remove the upper bearing by performing the following:

a. Lower the fork within the head tube as needed, and remove headset spacer, seal and bearing cover

(Figure 2-5).

b. First remove the upper bearing with Park RT-1 head cup remover, then the lower bearing (Figure 2-6).

Installation

1. If removed, install the upper bearing by performing the following:

a. Press top and bottom bearing cup and bearing using Park HHP-2 Headset Press (Figure 2-7).

b. Press the front fork up into the head tube.

c. Install the bearing cover, then the seal and headset spacer

2. Set the handlebar stem onto the head tube, and turn in the handlebar stem bolt and washer (A, Figure 2-4).

WARNING!

The handlebar stem bolt and clamp bolt must be tightened as described below. Overtightening

the stem bolt can damage the headset bearings. If the handlebar stem clamp bolt is not properly

torqued, the fork may not turn when the handlebar is turned.

3. Perform the following to set the headset bearings and to secure the handlebar stem in place and in

alignment with the front wheel.

a. Tighten the handlebar stem bolt (B, Figure 2-4) until there is no play in the steer- ing.

b. Tighten the stem bolt an additional 120 degrees (clockwise), and then loosen it 90 degrees

(counterclockwise).

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12 13

CHAPTER 3

BRAKES

WARRANTY NOTE: Brakes fall under “non-electric” component warranty. Applicable warranty is 6 months

from date of purchase. Any service issue resulting from misuse of bicycle is not covered under this warranty

and user shall be responsible for all charges.

BRAKE LEVER REMOVAL/INSTALLATION

Removal

1. Note the position of the throttle, shifter and display relative to its handlebar grip. If necessary, measure the

gap between the item and its handlebar grip or make a drawing so these components can be reinstalled

with the proper positioning and orientation. Also note the orientation of the handlebar within the handlebar

stem.

2. Disconnect the electric brake lever connector at the controller box.

3. At the brake lever, loosen the adjuster locknut (A, Figure 3-1) and turn the adjuster barrel (B, Figure 3-1)

from the brake lever.

4. Turn the adjuster barrel and the locknut until their slots align with the slot in the brake lever housing.

5. Pull the cable housing from the adjuster barrel (B, Figure 3-1), and slide the inner wire (C, Figure 3-1)

through the slots in the lever housing, adjuster barrel and locknut.

6. Press the brake lever toward the handlebar, and disconnect the inner wire end (A, Figure 3-2) from the

anchor (B, Figure 3-2) on the brake lever.

7. Remove the handlebar from the handlebar end.

Installation

1. Slide the new brake lever onto the end of the handlebar.

2. Make sure the slots in the adjuster barrel and the locknut align with the slot in the brake lever housing

(Figure 3-1).

FIGURE 3-1

BAC

3. Connect the end of the brake cable inner wire (B, Figure 3-2) to the anchor (A, Figure 3-2) on the brake

lever.

FIGURE 2-9

FIGURE 2-10

5. Remove the handlebar stem and the upper bearing as described in this chap- ter.

6. Lower the fork until the fork column clears the head tube, and remove the front fork.

7. Visually inspect the seal, bearing cover, spacer and stem cap for any damage (Figure 2-10).

8. Manually turn the bearing inner race, and conﬁrm that the bearing rotates smoothly.

9. Inspect the lower bearing in the head tube. If either bearing is faulty, replace both bearings as a set.

Installation

1. After installing the headset as previously referred, slide the fork column up into the head tube until the

lower-bearing collar rests against the lower bearing.

2. Install the handlebar stem as described in this chapter.

3. Install the front wheel.

4. Carefully slide the front brake caliper onto the brake disc so the disc does not mar the brake pads. Apply

Loctite 242 to the threads of caliper mounting bolts (A, Figure 2-9), and evenly tighten the bolts. Torque

the caliper mounting bolts to the speciﬁcation in Table 5.

5. Install the handlebar as described in this chapter.

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14 15

FIGURE 3-2

4. Pull the cable housing, and slide the cable inner wire (C, Figure 3-1) through the slots in the brake lever,

adjuster barrel (B, Figure 3-1) and locknut (A, Figure 3-1). Seat the cable housing ferrule into the adjuster

barrel.

5. Install a handlebar grip onto the handlebar end.

6. Slide the brake lever so its bracket seats against the throttle or shifter. Rotate the brake lever to the

position noted during removal, and torque the brake lever clamp bolt to the speciﬁcation in Table 5.

BRAKE CABLE INNER WIRE

Removal

The cable inner wire can be replaced without removing the cable housing.

1. Clip the cable ferrule from the brake cable inner wire.

2. Turn out the anchor bolt (A, Figure 3-3), and release the inner wire from the pinch mechanism.

4. Pull the cable housing and inner wire from the caliper barrel adjuster.

5. At the brake lever, loosen the adjuster locknut (A, Figure 3-1) and turn the adjuster barrel (B) from the

brake lever.

6. Turn the barrel adjuster and the locknut (A, Figure 3-1) until their slots align with the slot in the brake lever

housing.

7. Pull the cable housing from the adjuster barrel, and slide the inner wire (C, Figure 3-1) from the slots in

the housing, adjuster barrel and locknut.

8. Press the brake lever toward the handlebar, and disconnect the inner wire end (C, Figure 3-1) from the

anchor (B) on the brake lever.

9. Pull the inner wire from the cable housing until the far end emerges from the cable housing (A, Figure 3-2).

Installation

A fourth-hand tool (Park Took BT-2) is needed for this procedure.

1. Apply oil to the inside of the cable housing.

2. Insert the inner wire through the brake lever end of the cable housing until the wire emerges from the

caliper end of the housing.

3. Press the brake lever toward the handlebar, and connect the inner wire end (B, Figure 3-2) to the anchor

(A, Figure 3-2) on the brake lever.

FIGURE 3-3

4. Pull the cable housing, and slide the cable inner wire (C, Figure 3-1) through the slots in the brake lever,

adjuster barrel (B, Figure 3-1) and locknut (A, Figure 3-1). Seat the cable housing ferrule into the adjuster

barrel.

5. At the caliper, turn the barrel adjust all the way into the caliper.

6. Feed the inner wire through the caliper barrel adjuster, and seat the cable housing in the adjuster.

7. Route the inner cable through the pinch mechanism on the caliper.

8. Use the fourth-hand tool to remove the slack from the cable, and torque the brake caliper anchor bolt (A,

Figure 3-3) to the speciﬁcation in Table 5.

9. Loosen the CPS bolts with 5mm hex wrench(B, Figure 3-3) so the caliper can move freely.

10.Turn the inboard pad adjuster (C, Figure 3-3) clockwise (inward toward the caliper) until the brake disc

(A, Figure 3-4) is centered within the caliper body (B, Figure 3-3). The caliper is properly adjusted if the

space on each side of the brake disc is the same.

11.Pull in and hold the brake lever. Check that the rotor is still centered within the caliper body.

12.Pull in and hold the brake lever. Torque the CPS bolts (B, Figure 3-3) to the speciﬁcation in Table 5 while

holding the brake lever in.

13.Release the brake lever, and spin the wheel. Listen for the sound of the inboard pad rubbing against the

brake disc.

14.If rubbing is noted, turn the inboard pad adjuster counterclockwise (out from the caliper) two or three

clicks, and recheck.

15.Repeat Steps 13 and 14 as needed.

16.Trim the inner wire end so its end extends no more than 20 mm (3/4 in.) beyond the anchor. Crimp a new

cable ferrule onto the cable end.

17.Use the barrel adjuster (B, Figure 3-1) at the brake lever to remove any cable slack. Turn the adjuster

outward until brake lever freeplay is eliminated. However, do not go so far that the caliper torque arm is

moved. Make sure the caliper torque arm is completely released, and tighten the adjuster locknut (A)

against the brake lever housing.

ServiceManual_101212.indd 14-15 10/12/2012 12:25:50 AM

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