Thumper

Brake Setup

Before you can set up a brake correctly you first need to ensure all the parts are in good working condition, free in movement and that you have Material left on the pads. Don’t forget to check the disc as well to ensure it is not
warped, cracked, pitted or excessively grooved and worn (You may be able to see this by spinning the wheel), If not remove the wheel and take off the disc and check it on a flat smooth surface.
(Glass is naturally flat due the process of its making) .

Reassemble all the brake part if taken apart.
Remember to Oil all inner cables and moving parts to ensure free movement / operation.
(Don’t get oil or grease on the pads or the Disc)
If you do get contamination, remove immediately with a suitable solution
i.e. neat Petrol, thinners,

First undo and slacken off the brake cable to be adjusted
(Hold the barrel with an 8mm Spanner while you undo the Allen key grub screw).

Next we need to set the brake lever cable adjustment barrel, and adjust it to be about 2 turns out, from fully closed, ensure the locking ring is tightened against the lever.

We now need to check that the brake calliper arm is in the correct position. The arm of the brake calliper needs to be about 110 degrees past the alignment of the cable. If the lever is not in this position, remove and replace in correct position. Now lock the inner brake cable in this position.

Now the calliper lever as been set we can take up the excess play / travel in the brake lever by adjusting the brake pads closer to the disk.
Don’t adjust the pads by the brake lever cable adjustment barrel, this is for fine tuning.

First we need to back off the lock nut of the adjuster half a turn or until the Allen key screw in the centre turns freely.


Now Spin the wheel and Slowly Tighten (screw in) the Allen key screw in the centre of the brake calliper until the pads start to rub against the disc. Now back the adjuster off until it just stops rubbing.

Press the brake a couple of times to centre the calliper and the pads against the disc. Repeat the above until you are happy with the action and the feel at the lever is what you want. The brake should feel sharp and be able to stop the wheel suddenly at the beginning of its travel. There should still be a gap between the lever and the bars when the lever is fully pressed. If all is OK then tighten up the lock nut while holding the Allen key screw in place. (Don’t allow the Allen key screw to turn when tightening)

Now for the fine tuning, take the bike out for a spin and test the brake to see if the feel is ok, If this is not ok then you can do the following:-

1. Adjust the pad again. (by the adjusting pin)
2. Adjust the cable barrel at the lever.

Job done, Pat you’re self on the back and go on to the rear

The rear brake is the same process as the front.

Thanks to MMC (minimotoclub)

Tom