To ensure service brake linkage and park brake linkage are adjusted properly.
NOTE: The front end of the brake rod needs to be adjusted before the rear end of the brake rod.
Brake Rod Front End Adjustment:
1. Park machine on level surface and turn key switch OFF.
2. Shift lever in NEUTRAL and park brake lever in released position, and front wheels BLOCKED.
3. Raise cargo box.
4. Tighten nut (A) onto linkage (B) completely until the ends of sleeves (C) make contact inside spring (D). This sets a predetermined preload on the spring.
Brake Rod Rear End Adjustment:
NOTE: If this is a NEW transaxle or you have replaced the brake pack assembly, ONLY perform steps 1-5, and 7-9. New brake parts require a tighter linkage adjustment to account for initial break-in wear.
1. Use jack stands or hoist to raise rear wheels at least 25 mm (1.0 in.) off ground.
NOTE: If brake cable is being replaced, DO NOT attach cable to brake pedal at this time. Attach cable only at mid-frame mounting and brake arm assembly.
2. Disconnect brake arm return spring (E).
3. Loosen jam nut (F) and coupler nut (G).
4. Hold brake rod (H) to rear and brake arm (I) forward to remove all play.
5. Turn coupler nut (G) forward until it pushes spacer (J) and washer (K) forward until washer just contacts coupler pin (L).
6. Turn coupler nut (G) 3 turns (eighteen flats of nut) away from pin (L).
7. Tighten jam nut (F).
8. Install brake arm return spring (E).
9. Turn rear wheel, it should rotate with a slight drag and provide even braking on both sides.
NOTE: If no new parts have been installed, proceed to "Alternate Rear End Adjustment Procedure" below. (DO NOT proceed if NEW parts have been installed).
Alternate Rear End Adjustment Procedure:
(DO NOT use this step for NEW parts):
NOTE: When using torque wrench, the torque wrench centerline should intersect the axle flange centerline!
Using torque wrench, turn any lug of rear tire. Tire should rotate at less then 11 Nm (8 lb-ft), ideally 7 Nm (62 lb-in.).
Turn any lug of rear tire. Tire should rotate at less then 20 Nm (15 lb-ft), ideally.
After repeating procedure for both sides, check both sides (left and right) for EVEN braking. If NOT EVEN, repeat entire procedure.
NOTE: This completes the routine portion of brake adjustment procedure. If brake cable has been replaced or foot pedal linkage needs adjustment, complete "Brake Cable Adjustment" below.
Brake Cable Adjustment:
1. Ensure park brake is in released position.
IMPORTANT: Avoid damage! DO NOT allow brake cable to slip out of slot or cable may become kinked. Hold cable in slot by holding cable below lower nut (C) when loosening top nut (D).
2. Loosen cap screw(s) (A) of stop plate (B) and lower plate.
3. Loosen jam nuts (C) and (D).
4. Pull down on cable housing to take out all play in cable. Hold cable housing in place and tighten jam nuts (C) and (D).
NOTE: Brake pedal freeplay is necessary to prevent any preload of brake linkage. If stop plate (B) is adjusted too high, brakes will be preloaded. If stop plate is adjusted too low, return spring pressure, will kink brake cable.
5. Adjust stop plate (B) up to reduce amount of freeplay in brake pedal. Apply only enough up force to stop plate to take up freeplay. Do not start actuating brake.
6. Hold stop plate (B) while you tighten cap screw (A).
If light and horn kit is installed, stop plate will have a switch fastened to it. Stop plate must be positioned so switch is aligned with bottom of brake pedal rod (E). Be sure brake pedal rod contacts switch plunger (plunger depressed) but does not contact the switch body.