Polaris EV206PH-B User manual

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.
ServiceManual_101212.indd 40-1 10/12/2012 12:25:43 AM

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
ServiceManual_101212.indd 2-3 10/12/2012 12:25:43 AM

1
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
ServiceManual_101212.indd 4-1 10/12/2012 12:25:44 AM

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. 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. 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. Check charger.
Replace battery. Replace battery.
ServiceManual_101212.indd 2-3 10/12/2012 12:25:44 AM

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
ServiceManual_101212.indd 4-5 10/12/2012 12:25:44 AM

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)
1
7
8
2
6
4
3
5
9
10
REAR RACK MODELS (EV306PH-B, EV306PH-S,
EV316PH-G, EV316PH-L, EV407PH-G, EV407PH-B, EV417PH-W, EV417PH-B
1
7
8
2
64
3
5
9
10
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
ServiceManual_101212.indd 6-7 10/12/2012 12:25:45 AM

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
B
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
B
A
FIGURE 2-2
B
A
B
ServiceManual_101212.indd 8-9 10/12/2012 12:25:47 AM

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
B
A
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).
ServiceManual_101212.indd 10-11 10/12/2012 12:25:48 AM

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
B
A
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.
ServiceManual_101212.indd 12-13 10/12/2012 12:25:50 AM

14 15
FIGURE 3-2
B
A
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
B
A
C
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