Brake Maintenance Instructions

Over time, it is normal for the brake cable to stretch, or for the brake pads to wear down. Here is how to maintain the brakes on Boosted Rev. 

  1. First, spin the rear wheel while looking at the brake rotor to make sure that it has not been bent. If your brake rotor is straight, skip to the section of the article for checking and replacing the brake pads. If you notice any bends in the rotor, keep reading for how to replace the rotor. 

 

 

 

Brake Rotor Replacement

Difficulty Rating: 2-3

Estimated Time: 60 minutes

Tools you will need:

  • 21mm open-end wrench
  • 4mm hex key
  • 3mm hex keyRotor.jpg

  

Avoid touching the braking surface of your new brake rotor during the entire process. If you accidentally touch the braking surface, it can be cleaned with isopropyl alcohol. Any oils from your skin or other chemicals on the brake rotor can negatively affect the performance of the brake.


  1. In order to remove the brake rotor, you will need to remove your rear motor assembly. Follow the instructions found here. There is no need to remove the tire and tube, but follow the instructions to remove the wheel, motor cable, and brake rotor, then continue following the instructions to reinstall all of these components with the new brake rotor.

 

 

Brake Pad Replacement

Difficulty Rating: 2

Estimated Time: 15 minutes

Tools you will need:

  • 21mm open-end wrench
  • 3mm hex key
  • Optional: tweezers or narrow pliersBrake_Pads.jpg

 

With use, your brake pads will wear down. When they have worn down too much, you will need to replace them or the brake performance will be compromised. Inspect the brake pads if you notice a reduction in your brake performance.

 

  1. Take a look at your brake pads and take note of how much compound is left. If your brake pads are still in good condition, skip to the section of this article on correcting the caliper alignment. If your brake pads need to be replaced, keep reading.
  2. On the left-hand side of the scooter, you will find a plastic cap protecting the motor cable. In order to remove a wheel, you will need to first remove this cap using a 3mm hex key.image17.jpgimage18.jpg
  3. Remove the rear wheel from the scooter in two steps. 
    1. First, loosen the axle nuts on both sides with a 21mm open-end wrench or 8-10” adjustable crescent wrench. Do not fully remove the nuts.image10.jpgimage20.jpg
    2. Next, while supporting the wheel, slide the two washers away from the wheel. The wheel should now slide down, out of the fork. Set the wheel to one side.image12.jpg
  4. Now that the wheel has been removed, you should see two green tabs on the underside of the brake caliper. These tabs extend from the brake pads. Working on one at a time, use the tabs to pull the brake pads towards the center of the caliper then out. A pair of needle-nosed pliers or tweezers can help with this. The brake pads are held in with magnets, so this may take a little patience.image2.jpgimage21.jpg
  5. Once both brake pads are removed, insert your new brake pads into the center of the brake caliper, making sure that they ‘click’ as the magnets pull them into place.image15.jpg
  6. Separate the washers on both sides of the wheel, and begin sliding the wheel into the fork. Make sure the flat edges of the axle line up with the slot in the fork and that the cable is exiting the axle forward. On each side of the wheel, one washer should go on the inside of the fork, and the other should stay on the outside.image23.jpgimage26.jpg
  7. Once the wheel is completely seated in the fork, slide the outside washers into the indentation on the fork in order to lock the wheel in place.image16.jpg
  8. Now tighten the nuts on either side of the axle using your 21mm open-end wrench. Make these as tight as possible.image13.jpgimage9.jpg
  9. Use a 3mm hex key to reinstall the nut and bolt to hold the motor cable cap in place on the left side of the scooter. Be sure the bolt is passing through the keyhole in the scooter's chassis.image19.jpgimage6.jpg

 

 

 

Correcting the Caliper Alignment:

 

There are several reasons why you may want to correct the alignment of your brake caliper. Boosted Rev has a single-piston caliper meaning that only one side moves. If the stationary side is too far away from the brake rotor, warping may occur to the brake rotor. On the other hand, if the brake caliper is too close to the brake rotor, it will rub even when the brakes are not engaged. Here is how to correctly align the brake caliper.

Difficulty Rating: 1

Estimated Time: 5 minutes

Tools you will need:

  • 5mm hex key
  • Business cardCaliper.jpg

 

  1. First, loosen the two caliper mounting screws with a 5mm hex key. There is no need to fully remove these screws.image11.jpgimage28.jpg
  2. Insert a business card between the brake pad and the brake rotor. Make sure to slide it into the side that is closer to the wheel.image8.jpgimage22.jpg
  3. Squeeze the brake lever. This will center the brake caliper over the rotor so that there will be just the right amount of clearance between the inside brake pad and the brake rotor.image1.jpg
  4. While squeezing the brake lever, tighten the two screws from earlier with a 5mm hex key.image3.jpgimage25.jpg
  5. Release the brake lever, and remove the business card.image8.jpg
  6. Done!

 

 

 

 

Brake adjustment:

 

With use, it is normal for the brake cable to stretch slightly. This means that you may lose some of the braking force or that you will have to pull the brake lever more in order to feel the same amount of braking power. If this is the case for you, here is how to adjust the tension on your brakes.

 

Difficulty Rating: 1

Estimated Time: 5 minutes

Tools you will need:

  • 5mm hex key Brake_Adjustment.jpg
  1. Find the barrel adjuster on one side of the brake lever. Rotate the barrel counter-clockwise to put more tension on the brake cable. The more the barrel adjuster separates from the brake lever, the more tension will be held on the brake cable. Once the tension has been adjusted, twist the locking nut clockwise until it is snug against the lever body.image7.jpg
  2. If the brakes require more tension than can be accomplished with step one, you can adjust the cable closer to the brake rotor in two different ways. 
    1. There is another barrel adjuster where the cable housing ends. Follow the same instructions as above using this barrel adjuster.image14.jpgimage24.jpg
    2. If this is still not enough tension, you can loosen the cable pinch bolt and pull a little more of the cable through.image27.jpgimage5.jpgimage4.jpg




 

 

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