E-Z-GO MPT 800 Technician'S Repair And Service Manual Download

Page: 154 / 212

BRAKES - FRONT DISC

Page K-22

Repair and Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

ROUTINE MAINTENANCE

Tool List

Qty. Required

Shop rag.................................................................. A/R

Mechanics Mirror......................................................... 1

Flashlight ..................................................................... 1

Transmission fluid funnel............................................. 1

Torque wrench ft. lbs ................................................... 1

Torque wrench in. lbs. ................................................. 1

Crows foot 9/16", 3/8" drive......................................... 1

Open end wrenches 3/8", 1/2", 5/8", 9/16" .................. 1

Needle nose pliers....................................................... 1

Ratchet ........................................................................ 1

Sockets 3/8", 1/2", 5/8", 9/16" ..................................... 1

Micrometer/vernier caliper........................................... 1

2" C clamp ................................................................... 1

Floor jack..................................................................... 1

Jack stands ................................................................. 1

Ball Joint seperator...................................................... 1

Lug wrench, 3/4" ......................................................... 1

Jack ............................................................................. 1

Jack stands ................................................................. 4

Brake adjusting tool..................................................... 1

Plastic faced hammer.................................................. 1

Never work on a vehicle
s u p p o r t e d b y a j a c k
alone. To prevent possi-

ble personal injury, the vehicle must be supported on
jack stands during this procedure.

REPLACEMENT OF WEAR ITEMS

Brake Pad Replacement

Brake pads should always be replaced as a full set of
four pads. To remove the brake pads, raise the vehicle
per ‘Lifting the Vehicle’ in the SAFETY section. Loosen
both of the bolts securing the caliper to the spindle but
only remove one. Swing the caliper free from the rotor.
Push out the two guide/retainer pins from the caliper and
remove the pads, being careful to note the orientation of
the brake pads. Install a new set of pads. If the pads
have been correctly oriented, the guide pins will easily
engage. Re-insert the guide/retainer pins, being sure that
they are correctly seated in the grooves machined in the
caliper casting. Gently push the pads away from each
other to provide adequate clearance with the rotor and
then swing the entire caliper and pad assembly back

over the rotor. Secure the caliper to the spindle and
tighten both bolts to 25 - 30 ft. lbs (33 - 40 Nm) torque.
NOTE: Unless fluid is lost or a brake line is disconnected,
there is no need to bleed the system.

Rotor Replacement

The rotor (disc brake hub) is not designed to be
trued (“turned”).

If the rotor has deep grooves or gouges, it must be
replaced. If the pad contact area has worn the rotor to
.120" (3 mm) or less, the rotor must be replaced.

If the rotor must be replaced (or serviced), the caliper
and pads must be swung out of the way to gain access to
the rotor (See Brake Pad Replacement).

The disc hub (rotor) can be serviced in the same manner
as the hub on non-front disc brake equipped vehicles.

For Hub Replacement, Wheel Bearing and Race
Replacement, Wheel Bearing Packing and Wheel Bear-
ing Adjustment procedures, see FRONT SUSPENSION
AND STEERING.

Spindle Replacement

See FRONT SUSPENSION AND STEERING.

Actuator Linkage Bushings

Removing the front shield may improve access (See
BODY)

The actuator linkage is connected to the lower actuator
pivot with a flat washer and cotter pin. Remove and dis-
card the cotter pin and remove the washer. A new nylon
bushing may be installed (flange down) to the lower actu-
ator pivot and the actuator linkage reinstalled using a
new cotter pin. The actuator linkage is connected to the
brake pedal arm with a flat washer and cotter pin.
Remove and discard the cotter pin and remove the
washer. A new nylon bushing may be installed (with the
flange between the actuator linkage and the brake pedal
arm) to the lower actuator pivot and the actuator linkage
reinstalled using a new cotter pin.

Actuator Pivot Bushings

Removing the front shield may improve access (See
BODY)

Both the upper and lower actuator pivots contain an ace-
tal flanged bushing at either end of the actuator and are
unlikely to require replacement. The upper actuator pivot
also is fitted with a nylon bushing between it and the
brake cylinder clevis. To replace any of these bushings,
the actuator linkage must be removed from the lower