-194-
CHASSIS
- 194-
REPLACING THE REAR BRAKE PADS
1. Measure:
• brake pad wear limit
○
a
Out of specification
Replace the brake
pads as a set.
Brake pad wear limit
1.5 mm (0.06 in)
2. Install:
• brake pads
• brake pad spring
1
NOTE
:
Always install new brake pads, new brake
pad shims, new insulators, and a new brake
pad spring as a set.
3. Check:
• brake fluid level
4. Check:
• brake pedal operation
Soft or spongy feeling
Bleed the brake
system.
DISASSEMBLING THE REAR BRAKE
CALIPER
WARNING:
• Brake caliper is one of the most important
security components. Disassembly and
maintenance must have a rich experience
in technology and complete tool.
•Wrong disassembly and reassembly may
cause serious injury and even death.
Replace damaged brake caliper.
•If only replace the brake caliper of one side,
please check carefully whether the braking
force of right and left are balance and equal.
1. Remove:
• brake caliper piston
①
• dust seal
②
• caliper piston seal
③
a. Turn the brake caliper piston counterclockwise
to remove it.
CHASSIS
- 195-
b. Remove the dust seal and caliper piston seal.
1
WARNING
:
All internal brake components should b
e
cleaned in new brake fluid only. Do not us
e
solvents as they will cause seals to swell a
nd
distort.
1. Check:
• brake caliper pistons
①
Scratches/rust/wear
Replace the brake
caliper assembly.
• brake caliper cylinders
②
Wear/scratches
Replace the brake
Caliper assembly.
• brake caliper body
③
Cracks/damage
Replace.
• brake fluid delivery passage (brake caliper
body)
Blockage
Blow out with compressed air.
1
WARNING
:
Replace the caliper piston seals and
dust
seals whenever the brake caliper
is
disassembled.
ASSEMBLING THE REAR BRAKE CALIPER
1
WARNING
:
• All internal brake components should be
cleaned and lubricated with new brake flu
id
only before installation.
Must use DOT4 Brake Fluid
• Replace the caliper piston seal and du
st
seal whenever a brake caliper is
disassembled.
1. Install:
• caliper piston seal
①
• dust seal
②
2. Install:
Summary of Contents for HS200UTV
Page 3: ......
Page 15: ......
Page 94: ... 79 SPECIFICATIONS 79 HYDROGRAPHIC CHART Hydrographic chart Pressure ...
Page 95: ... 80 SPECIFICATIONS 80 LUBRICATION OIL WAY LUBRICATION OIL WAY Pressure splashing oil ...
Page 248: ... 233 CHASSIS 233 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise ...
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