Argo Service Manual Brake System SECTION BR Brake System Table of Contents General Instructions.......................................................................................... BR3 Brake System Maintenance............................................................................... BR4 Maintenance Schedule....................................................................................... BR4 Hydraulic Brakes...................................................................................
Brake System Argo Service Manual Master Cylinder Reassembly.................................................................................BR23 Master Cylinder Installation.................................................................................. BR24 Bleeding the Hydraulic Brake System (HDi)........................................................ BR25 Bleeding the Brakes................................................................................................
Argo Service Manual Brake System General Instructions Always refer to the correct PARTS MANUAL in accordance with the specific model and serial number indicated on the serial tag plate of your vehicle. This is essential to locating and ordering the correct components that were used during that particular manufacturing period when the ARGO was built. It is also very helpful using the illustrations to clearly see and define the component being referred to.
Brake System Argo Service Manual Brake System Maintenance CAUTION Regular maintenance of the brake system is essential to both good vehicle performance and personal safety. Poorly maintained brakes can result in a decrease in braking/steering efficiency, vehicle performance or damaged brake discs. Maintenance Schedule 1. Every 100 hours of vehicle operation, perform the servicing procedure, Brake Pad Inspection ( Mechanical). 2.
Argo Service Manual Brake System Hydraulic Brakes General Although the hydraulic brake system is self adjusting, the following require periodic attention: Brake Fluid Level (Steering Brake Master Cylinders) After every 50 hours of operation, check the brake fluid level by removing the master cylinder covers. IMPORTANT Thoroughly clean the master cylinder cover and surrounding area before removal. The master cylinders are mounted tilted slightly back.
Brake System Argo Service Manual Brake Fluid Level (Service Brake Master Cylinder) The ARGO HDi is equipped with a hydraulic handbrake system. This consists of an independent set of hydraulic brake calipers and brake discs. The master cylinder is mounted on the left side steering bar. The master cylinder is not serviceable nor replaceable. Complete hand brake/master cylinder assembly must be replaced. Photo A Photo A Monitor the hand brake fluid on a regular basis.
Argo Service Manual Brake System Replace the pads when: • the brake lining material molded to each metal backing plate is worn to 0.10" thickness. (Figure 2). • the pads are glazed and brake performance is affected. • the pads are contaminated with lubricant, and brake performance is affected. Figure 1 Figure 2 Removing the Steering Brake Pads (Gremica Calipers) Avengers Manufactured Prior to Serial No.
Brake System Argo Service Manual NOTE You may leave the brake fluid line connected to the caliper. The left hand caliper requires the removal of the drive belt and driven clutch to access the mounting bolts to the transmission. Refer to, Removing the Driven Clutch, and Removing the Drive Belt, in Section CS of this service guide. 4. Remove the 2 socket head fasteners and flat washers (later models utilize lockwashers). Photo 1 Slide the caliper from the brake disc. 5.
Argo Service Manual Brake System Installing Steering Brake Pads (Gremica Calipers) Vehicles Manufactured prior to Serial No. 21245 NOTE When replacing brake pads, always use new cotter pins. NOTE Before installing new pads, use brake cleaner on rotor and caliper to remove contaminants and oil. CAUTION When replacing worn or contaminated pads, replace both pads in the brake caliper assembly even if both pads do not require replacing.
Brake System Argo Service Manual Removing the Steering Brake Pads (Knott Calipers) Avengers Manufactured From Serial No. 21245 Brake pads are easily replaced by removing the 2 cotter pins securing them within the Figure 3 brake caliper assembly and pulling each pad up and out of the caliper. See Figure 3. Pistons have to be pushed back in first, to allow clearance for the new pads. Slip the new pads into the caliper and install 2 new cotter pins bending the ends over to secure the pads in position.
Argo Service Manual Brake System Brake Pad Inspection Procedure (HDi - Service Brake Pads) Inspect the brake pads after every 25 hours of operation. Worn, glazed or contaminated brake pads affect the efficiency of the brake system. To inspect the pads, first remove the firewall. With the firewall removed, both handbrake hydraulic brake calipers are visible. Each caliper has 2 brake pads which are secured by (2) 3/8” Socket Head bolts. Inspect all 4 brake pads.
Brake System Argo Service Manual Installing the Service Brake Pads (HDi) NOTE Before installing new pads, use brake cleaner on components before re-assembly to remove oil and other contaminants. CAUTION Ensure the brake pads are NOT installed backwards. The pad side must be installed towards the brake disc. The brake pads utilize a black coloured anti-squeal coating on the opposite side of the pad which could be mistaken for the pad surface. 1.
Argo Service Manual Brake System 5. After the 10 cycles are complete shut down the Argo and allow at least 30 minutes for the brakes to cool down. 6. Once the brakes have sufficiently cooled down, repeat the entire process a second time following steps 1-3. 7. The bedding in procedure is now complete Hydraulic Brake Calipers Maintenance Schedule - Inspect every 50 hrs of vehicle operation CAUTION The brakes must be inspected regularly by a qualified authorized Argo dealer/mechanic.
Brake System Argo Service Manual Remove Hydraulic Brake Caliper IMPORTANT Argo Avengers have been manufactured with two brands of brake calipers during specific build periods. Earlier vehicles (Avengers manufactured prior to serial no. 21245), utilized a Gremica brand caliper (typically black in colour). Current models use Knott brand calipers (typically silver in colour). The following procedure illustrates a Gremica rebuild.
Argo Service Manual Brake System NOTE The left hand caliper requires the removal of the drive belt and driven clutch to access the mounting bolts at the transmission. Refer to Removing the Driven Clutch in Section CS of this service guide. NOTE When removing the caliper from the transmission, take note of any shims that may have been used between the caliper and transmission mounting boss. Earlier models may have employed shims to correctly align the calipers with the brake discs.
Brake System Argo Service Manual Photo 8 Photo 9 5. Take the caliper assembly from the vise and separate the 2 halves. Photo 10 6. Lift the piston seals and Photos 11 & 12 small “O” ring from the caliper halves and discard. 7. Remove the bleed screws and check the steel ball from the caliper casting. Photo 13 8. Clean all components in a varsol bath, then a mild soap solution. Use compressed air to blow out the caliper castings.
Argo Service Manual Brake System Photo 12 Photo 13 9. Wipe all components with a lint free cloth or use compressed air to dry. 10. Thoroughly inspect all the components. Replace any worn, cracked, broken or missing parts. 11. Inspect both piston chambers for any pitting, scratching, scarring or rust. Replace pistons with new, or the entire caliper assembly if necessary. Hydraulic Brake Caliper Reassembly 1. Begin with all the components on a clean work surface. 2.
Brake System Argo Service Manual Photo 14 CAUTION Photo 15 Do not scratch or tear the seals during installation. Any damaged seal must be replaced immediately. 5. Insert the pistons so that the cavity side is facing up. 6. Place the one half caliper into the aluminum jawed vise being careful not to damage it by overtightening it. Locate the oil journal which requires the small “O” ring. Place the “O” ring over the hole making sure that the flat edge of the ring is facing down.
Argo Service Manual Brake System NOTE Knott Calipers are secured together by four (4) Hex Head Cap Screws, Eight (8) Flat Washers, and four (4) Fin Hex Nuts. Photo A 8. Reinstall the Socket Head Cap Screws (Gremica Calipers) which hold the caliper assembly together. Use blue LOCTITE 243 on the threads of the fasteners. Torque the bolts to the specified torque. Photo A Photo 18 9. Place the check ball and bleed screw back into the threaded mount of the caliper casting. Photo 19.
Brake System Argo Service Manual NOTE When re-installing the calipers to the transmission, ensure any shims that may have been used between the caliper and transmission mounting boss are re-installed. Earlier models may have employed shims to correctly align the calipers with the brake discs. WARNING NEVER attempt to align these with the engine running and in gear. Photo 21 Photo 22 12. Re-attach the brake line at master cylinder.
Argo Service Manual Brake System This will result in a loss of braking/steering effectiveness. NOTE To rebuild a master cylinder, removal of the component is necessary to ensure a clean and thorough job. IMPORTANT Argo Avengers have been manufactured with two brands of Master Cylinders during specific build periods. See chart below for information on what brand your Argo was manufactured with. The following procedure illustrates a Gremica Master Cylinderrebuild.
Brake System Argo Service Manual Photo 24 Photo 26 Photo 25 Photo 27 Disassembling the Master Cylinder (Gremica - typically black in colour) 1. Perform the servicing procedure, Master Cylinder Removal 2. Pull the piston and compression spring from the master cylinder. Photo 27 CAUTION Do not use a gripping tool to pull out the piston as this will scratch or damage the surface. Use fingers only to pull out the piston.
Argo Service Manual Brake System 4. Clean all components with alcohol or a mild soap solution. Use compressed air to blow out the master cylinder castings. This will free up any dirt or other contaminants you could not reach with the cloth. Master Cylinder Servicing & Inspection NOTE Use only genuine ARGO parts. 1. Thoroughly inspect all components of the master cylinder assembly and replace any worn, cracked or broken parts. 2. Inspect the condition of the piston.
Brake System Primary Seal Argo Service Manual Secondary Seal Photo 28 Photo 29 2. Install the compression spring to the brake plunger. Photo 29 3. Install the spring & plunger into the piston bore. Slide the end with the primary seal in first. Photo 30 Photo 30 Photo 31 4. Temporarily install the cover and gasket onto the master cylinder reservoir. Master Cylinder Installation 1. Line up the holes in the mounting bracket with those of the master cylinder and insert the 2 mounting bolts.
Argo Service Manual Brake System Bleeding the Hydraulic Brake System (HDi) IMPORTANT The position at which the brake calipers are mounted on both 34-100 and 34-200 transmissions is less than ideal for optimum bleeding and purging of air from the system. In order to bleed and purge all air from the brake system successfully, the calipers should be removed and remounted vertically. Ensure also master cylinders are level. This may require raising the back end of the vehicle slightly.
Brake System Argo Service Manual Right Side Caliper Photo 39 Photo 40 5. Insert a piece of .250" Flat Bar between the pads to simulate the thickness of the brake disc. Photos 41 & 42 Right Side Caliper Left Side Caliper Photo 41 Photo 42 Bleeding the Brakes 1. Remove master cylinder covers and add DOT 5 (ONLY) brake fluid as necessary. 2. Remove the rubber plug from the bleed screw at the brake caliper. 3.
Argo Service Manual Brake System screw gradually until fluid slowly releases. Repeat this procedure until the fluid coming from the bleed screw is a full stream with no visible signs of air in the system. NOTE Catch any purged fluid at the caliper bleed screw with a rag or small container of some sort. 5. Replenish the master cylinder to the top of the viewing window and secure the cover and rubber gasket. 6.
Brake System Argo Service Manual the idler chains. Photo 44A Attach here Right Hand Brake Caliper Photo 43 Parking brake Caliper 1/4" Flat Bar Spacer Photo 44 Photo 44A Photo 45 4. Insert a piece of .250" Flat Bar between the pads to simulate the thickness of the brake disc. Photos 45. 5. Perform the servicing procedure, Bleeding the Brakes. 6. Remove the caliper from the brake disc and remount back to the original location. 7.
Argo Service Manual Brake System Left Hand Brake Caliper 8. Route the Left side brake caliper over to the right side of the transmission to mount it to the right side brake disc. The caliper will need to be mounted backwards to have the mounting holes closest to the brake disc. Mount using enough washers to space it out from the idler chains. Photo 46 (2) Spacers Photo 46 Left Hand Brake Caliper 9. Insert a piece of .
Brake System Argo Service Manual CAUTION Regular inspection of the brake fluid is very important. Low fluid levels can cause a reduction or loss in braking ability; high fluid levels, or brake fluid contaminated with oil, dirt, or water, can damage the seals or other component parts of the hydraulic brake system. Inspecting the Brake Fluid Condition Maintenance Schedule- Inspect every 50 hours of vehicle operation. Use only Dot 5 silicon brake fluid.
Argo Service Manual Brake System 1. To drain and replenish the brake system you will need to remove the firewall of the vehicle. Perform the servicing procedure, Removing the Firewall for your particular model in Section VB of this service guide. 2. Remove the engine hood to access the master cylinders. Remove both covers using the appropriate screwdriver. 3. Locate the bleed screw on the hydraulic brake caliper.
Brake System Argo Service Manual Disassembling the Service Brake Calipers 1. Remove the service brake master cylinder cover (located on the left hand steering bar) and remove the fluid from the bowl. Use a vacuum type pump. Photo 49 Cover 2. Loosen the brake line banjo bolt at the service brake caliper. Photo 50 3. Locate and remove the two (2) fasteners securing the Service Brake Caliper to the mounting Bracket. Photo 51 Photo 49 Photo 50 Photo 51 4.
Argo Service Manual Brake System Flat Washer Bleeder Screw Air Nozzle Photo 52 Photo 53 7. Remove the two fasteners securing the caliper halves together and separate. Photo 54 & 55 Photo 54 Photo 55 8. Remove the piston from the caliper. Pry and pull the seal along with piston. Photo 56 & 57 9. Strip the seal from piston. Photo 58 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421 BR-33 www.argoutv.
Brake System Photo 56 Photo 58 Argo Service Manual Photo 57 Photo 59 10. Remove bushings from the mounting bolt caliper holes and remove a rubber O-Ring beneath each. Photo 59 & 60 11. Photo 60 Wipe all components with a lint free cloth or use compressed air to dry. Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421 BR-34 www.argoutv.
Argo Service Manual Brake System 12. Thoroughly inspect all the components. Replace any worn, cracked, broken or missing parts. 13. Inspect piston chamber for any pitting, scratching, scarring or rust. Replace piston with new one that comes with kit or the entire caliper assembly if necessary. Re-Assembling the Service Brake Calipers 1. Lubricate all component parts with clean fresh Dot 5 Silicon Brake Fluid. 2.
Brake System Argo Service Manual 6. Lubricate and install mounting hole bushings to O-Rings installed in Step 2. Photo 54 7. Assemble the caliper back together and torque to specifications. Photo 55 Photo 54 Photo 55 8. Loosely re-attach the brake line to the Service Brake Caliper (Photo 56) and assemble the caliper and brake pads back to the vehicle. Photo 57. Torque mounting bolts to specifications.
Argo Service Manual Brake System 9. Torque the brake line banjo bolt to specificiations. USE NEW COPPER WASHERS ON THE BANJO BOLT. Bleeding the Hydraulic Brake System (Service Brakes) 1. Remove master cylinder cover and add DOT 5(ONLY) brake fluid as necessary. 2. With the bleed screw still tight, purge any air from the system by pumping the brake lever slowly.
Brake System Argo Service Manual Hydraulic Brake Plunger Pin Adjustment IMPORTANT It is critical that the master cylinder pistons are adjusted properly when the steering handlebars are in the centred position. Overheating of the brake system could occur due to the piston being adjusted too far in. This could cause a drag on the system and a possible brake lockup or brake fade.
Argo Service Manual Brake System IMPORTANT Ensure the tab stops that the collars come into contact with are not bent in any way (Photo 59). This will affect how the plunger pin sits when the opposite brake is applied. Any deformity in the tab could cause the plunger pin to become misaligned with it's own steering arm during the application of the opposite brake. 4. Thread the plunger pins until the master cylinder plunger piston is flush with the casting of the master cylinder.
Brake System Argo Service Manual 3. Disconnect the hydraulic hose from the master cylinder. 4. Replace the hose. 5. Reconnect the hydraulic hose to the master cylinder. Make sure both copper washer seals have been replaced with new ones at the banjo bolts. Torque to specifications. 6. Perform the servicing procedure, Bleeding the Hydraulic Brake System. Brake Disc Inspection Maintenance Schedule - Inspect every 50 hrs. of vehicle operation.
Argo Service Manual Brake System NOTE If removing the LEFT side brake disc you will need to remove both Drive Belt and Driven Clutch to successfully work on and remove the brake disc. Brake Caliper Removed Photo 62 Photo 63. 4. Perform the servicing procedure, Removing the Idler Chain 5. Locate the outer retaining ring at Idler Sprocket and remove from groove. Slide it away from the sprocket. Slide sprocket up against retaining ring. Photo 64 & 65 Photo 64 Photo 65 6.
Brake System Argo Service Manual Photo 66 Photo 67 8. Perform the servicing procedure, Brake Disc Inspection. Installing a Brake Disc (Models with 34-100 Transmission) 1. Apply anti-seize compound to the spline of the output shaft. 2. Align the splines of the brake disc with those of the output shaft and slide the brake disc on to seat up against the shoulder. Photo 68 IMPORTANT The brake disc should slide on by hand. Do NOT force or hammer to install. 3.
Argo Service Manual Brake System Photo 70 Photo 71 5. Perform the servicing procedure, Installing the Idler Chain Removing Steering Brake Disc (HDi) IMPORTANT Refer to your illustrated parts manual for correct hardware identification and location. Refer to Vehicle Torque Chart for all specified torques. 1. Remove the two (2) fasteners securing either left or right hand side Service Brake Caliper at the brake bracket. Photo 79 Photo 79 Photo 80 2.
Brake System Argo Service Manual Photo 81 Photo 82 3. Rotate the Steering Brake Disc until the access hole in the disc is aligned with the brake fastener that secures it to the transmission. Remove the fastener. Photo 82 4. Rotate the brake disc to align it with the second fastener securing the brake caliper. Photo 83 5. Remove the second fastener. Photo 84 Photo 83 Photo 84 6. Slide the Steering Brake Caliper from the disc.
Argo Service Manual Brake System Photo 85 Photo 86 7. Remove one fastener from the inner Idler Shaft Coupler and Service Disc Brake. Photo 87 NOTE There is a lockwasher and locking nut to the inside of the fastener which will need to be held with an open end wrench. 8. Remove the fastener securing the Steering Brake Disc to the output shaft. Photo 88 Photo 87 Photo 88 9.
Brake System Argo Service Manual Photo 89 Photo 90 10. Slide the brake disc from the output shaft and free of the transmission. Photo 90 11. Perform the servicing procedure, Brake Disc Inspection. Installing the Steering Brake Disc (HDi) 12. Apply anti-sieze compound to the splined output shaft and install the Steering Brake Disc securely up against the shoulder of the output shaft. Photo 91 NOTE Use brake cleaner on components before re-assembly to remove oil and other contaminants.
Argo Service Manual Brake System 14. Align the mounting ears of the caliper with mounting bosses on transmission housing. Photo 93 15. Secure the caliper by applying Blue 243 LOCTITE to threads of the two (2) fasteners and mounting it to the transmission (along with a lockwasher). Torque to specifications. Photos 94 Photo 93 Photo 94 16. Blue LOCTITE the hardware required to secure the brake disc and torque to specifications. Photos 96 & 97 Photo 96 Photo 97 17.
Brake System Argo Service Manual 18. Locate the Service Brake Caliper bracket and reassemble the Service Brake Caliper securely into place. Photo 100 19. Torque to Specifications. Photo 101 Photo 98 Photo 99 Photo 100 Photo 101 Removing the Emergency/Parking Band Brake (HDi) prior to serial # P34521 & D17577. See page BR-53 for serial nunbers from P34521 & D17577 1. Perform the servicing procedure, Removing Steering Brake Disc (HDi) for RIGHT HAND side steering brake disc. 2.
Argo Service Manual Brake System Photo 102 Photo 103 3. Slip the band brake out of the mounting assembly while keeping the mounting assembly intact. Photos 104 4. Remove the cable from the brake band by removing the two slotted pins. Photo 105 Photo 104 Photo 105 Installing the Emergency/Parking Band Brake (HDi) 1. Locate and install the Emergency/Parking Brake Cable to the Brake Band assembly.
Brake System Argo Service Manual Photo 106 IMPORTANT Please ensure all Spacer Washers are in place on the Mounting Bolts before reattaching to the transmission housing. There are three (3) Spacers per bolt. Photo 107 NOTE Use brake cleaner on components before re-assembly to remove oil and other contaminants. 3. Slip the Band Brake over the E Brake Drum and secure to the transmission with the two (2) Bolts. Torque to specifications. Photo 108 & 109 Photo 108 Ontario Drive & Gear Limited PH.
Argo Service Manual Brake System 4. Apply anti-seize compound to the steering brake shaft and reinstall the Steering Brake Disc. Torque to specifications. 5. Re-install fastener back to the inner Idler Shaft Coupler and Service Disc Brake. Photos 110 & 111. Torque to specifications. 6. Locate the Service Brake Caliper bracket and reassemble the Service Brake Caliper securely into place. Photo 112 7. Torque to Specifications.
Brake System Argo Service Manual 3. You should also be able to grab the metal “J” bend at the end of the cable where the adjusting nut is and move it up and down, essentially moving the band and pins in the mounting bracket slots. This shouldn’t feel tight either. Photo 115 Photo 115 Photo 114 ` IMPORTANT If the band is too tight it will drag and the operator may experience a sluggish vehicle and notice smoke coming from the engine compartment.
Argo Service Manual Brake System the pads to wear prematurely. If the 5th position (click) does not provide full engagement with normal firm effort (extra effort for the 6th) adjust the cable accordingly. Loosen the jam nut at the caliper and adjust as needed. Reduce distance "A" to provide more braking force or increase distance "A" if brake does not turn freely. Removing Emergency/Park Disc Brake and Pads (from serial # P34521 & D17577) 1.
Brake System Argo Service Manual 4. Remove brake bracket and brake disc simultaneously. Photo 3 5. Set brake bracket to a clean work surface to remove brake pads. Photo 4 Photo 3 Photo 4 6. Remove both stover nuts securing brake pad bolts. Photo 5 7. Slip pads from bracket. Photo 6 Photo 5 Photo 6 8. Install new pads, matching the concave of the brake pads with the concave of the brake bracket. Photo 7 Photo 7 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421 BR-54 www.
Argo Service Manual Brake System 9. Install shoulder bolts and secure new pads with stover nuts. Photo 8 10. Ensure cable connections are secure at bracket. Photo 9 Photo 8 Photo 9 11.Locate mounting hardware and spacers to remount bracket to transmission. Photo 10 12. Locate brake disc and observe shoulder side of disc. Photo 11 Photo 10 13. Insert the brake disc between the brake pads with shoulder of disc facing in towards transmission.
Brake System Argo Service Manual Photo 13 Photo 14 14. Apply blue 243 LOCTITE to top (shorter) mounting bolt and install (with spacer) to brake bracket. Photo 14. Secure mounting bolts. 15. Secure parking disc brake with retaining ring. Photo 15 16. Ensure parking cable at linkage is secure. Photo 16 Photo 15 17. Re-install steering brake disc. Ensure machined concave area of disc, aligns with mounting bolt on caliper to avoid interference when slipping the disc back on to the shaft.
Argo Service Manual Brake System 18. Apply blue 243 LOCTITE to the threads of the steering brake disc mounting bolt and install. Torque to specifications. Photo 18 19. Re-install nut and lockwasher to coupler bolt removed in earlier steps and torque to specifications. Photo 19 Photo 18 Photo 19 20. Reinstall steering brake caliper. Apply blue 243 LOCTITE to mounting bolts and torque to specifications. Photo 20 21. Reinstall service brake caliper.
Brake System Argo Service Manual Emergency/Parking Brake Adjustment (750EFI/700 Models) NOTE Both left and righthand side emergency/parking brake caliper pads should be changed in pairs. Do not attempt to just replace one side. The emergency/parking brake system has been factory adjusted to ensure proper braking effectiveness. However, before the vehicle is used for the first time, and after every 25 hours of operation, the adjustment of the brake must be inspected.
Argo Service Manual Brake System Photo 119 Photo 120 6. Loosen the castle nut until it can be threaded by hand. 7. Using a 0.004" feeler gauge or a piece of regular photo copy paper (such as used for these instructions), slip it between the emergency/parking brake pad and brake disc. Ensure that you push the opposite side pad up against the brake disc before setting this gap. 8.
Brake System Argo Service Manual Parking/Emergency Brake Disassembly (Mechanical Caliper) NOTE Both left and righthand side emergency/parking brake caliper pads should be changed in pairs. Do not attempt to just replace one side. 1. Locate the emergency/parking brake caliper attached to the main brake caliper. Photo 121 (Left hand side example). 2. Locate the castle nut at the brake cam lever and remove the cotter pin and castle nut. Photo 122. Photo 121 Photo 122 3.
Argo Service Manual Brake System 5. Split and remove the caliper assembly. Photo 125 Take note of all spacers, shims and washers within the assembly. Refer to your illustrated parts list in your Argo Parts manual for all locations of these components. Photo 125 6. Locate the 850-84 Dead Side Brake Housing and remove the screw securing the brake puck. Remove the brake puck and discard. Photo 126 7. Locate the Live Side Brake Housing and turn upside down to remove 2nd brake pad from the housing cavity.
Brake System Argo Service Manual 10. Locate the live side brake housing and slip the shim washer into the cavity first (Photo 128), before installing the brake pad. 11. Install the second brake pad to the top of the previously installed shim. Photo 128 Reassembling the Emergency/Parking Brake Caliper to the Vehicle NOTE ` The following example illustrates the assembly of the left hand side Emergency/ParkingBrake Caliper.
Argo Service Manual Brake System Photo A Photo B 12. Install the live side housing to the inside of the brake disc. Insert (2) mounting bolts with spacers to the head of each bolt. Place a thin washer (to each bolt) on the inside of the mounting bracket. Photo 129. 13. Install the shim plate over the (2) mounting bolts. Photo 130 14. Next, install (2) thick washers to the mounting bolts along with the dead side housing which is placed to the outside of the brake disc. Photo 131 15.
Brake System Argo Service Manual Photo 131 Photo 132 16. Secure with the nylon locknuts and torque to specifications. Photo 133 17. Install the compression spring to the stud of the live side housing. Photo 134 Photo 133 Photo 134 18. Install the (2) dowel pins to the cavities of the live side housing (rounded side facing out). Photo 135. 19. Locate the brake lever assembly and reattach the extension spring to the hole provided.
Argo Service Manual Brake System Photo 135 Photo 136 20. Install the lever to the stud of the live side housing. Photo 137 Photo 137 21. Start the castle nut but do not tighten down yet. 22. Perform the servicing procedure, Emergency/Park Band Brake Adjustment (750EFI/700 Models) Removing the Service Brake Disc 1. Perform the servicing procedure, Removing the Floor Pan. 2. Perform the servicing procedure, Removing the Front Floor Pan. 3.
Brake System Argo Service Manual Photo 138 Photo 139 4. Remove both Front and Mid Front Chains connected to the Output Shaft Assembly. Photo 140 & 141. Refer to servicing procedure, Removing a Drive Chain if necessary. Photo 140 Photo 141 5. Remove the five (5) fasteners securing the Output Shaft Assembly to the Output Shaft Coupler. There is a nut to the inside of each fastener. Photo 142 & 143 6. Locate the (2) set screws at the outer bearing and loosen. Photo 144 7.
Argo Service Manual Brake System Photo 142 Photo 143 Photo 144 Photo 145 8. Tilt Output Shaft Assembly up and slide out of Outer Bearing to remove from vehicle. Photo 146 9. Remove the Speedo Sensor as it will interfere when removing Output Shaft Coupler. Photo 147 Photo 146 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421 BR-67 Photo 147 www.argoutv.
Brake System Argo Service Manual 10. Slide Output Shaft Coupler from splined Output Shaft. Photo 148 11. Remove Service Brake Disc. Photo 149 Photo 148 Photo 149 12. Perform the servicing procedure, Brake Disc Inspection. Installing the Service Brake Disc 1. Slip the Service Brake Disc over the splined Output Shaft. Photo 150 & 151 Photo 150 Photo 151 2. Apply anti-seize to spline of Output Shaft and install coupler up against the Brake Disc Photo 152 & 153.
Argo Service Manual Brake System 3. Insert the Output Shaft Assembly into Outer Bearing by tilting it upwards and then levelling out to connect to Output Shaft Coupler. Photos 154 & 155 Photo 154 Photo 155 4. Install the five (5) fasteners required to connect Output shaft Assembly to Coupler and torque to specifications.
Brake System Argo Service Manual 8. Reinstall the Speedo Sensor and set gap between sensor and pickup. Set gap between 1/8" and 3/8" Photo 161 9. Reinstall Service Brake Caliper to Caliper Bracket and torque to specifications. Photo 162. NOTE Use brake cleaner on components before re-assembly to remove oil and other contaminants. Photo 158 Photo 159 Photo 160 Photo 161 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421 BR-70 www.argoutv.
Argo Service Manual Brake System Photo 162 Disassembling the Moto Cross Style Steering Column 1. Perform the servicing procedure, Removing the Firewall. 2. Cut the tie wrap securing cables to the steering column. 3. Remove the (4) fasteners securing the steering bar to the steering column assembly. Photo 163 Photo 163 Photo 164 4. Remove the Nylon Locknut and Flat Washer from the top of the Lower Handle Bar Clamp. Discard the nylon locknut. Photo 164 Ontario Drive & Gear Limited PH.
Brake System Argo Service Manual 5. Remove the Lower Handle Bar Clamp from the steering shaft. Photo 165 IMPORTANT Be aware of the small key(s) installed into the steering shaft and ensure they are installed when reassembling the steering system. 6. Disconnect the hand brake lever cable at the steering arms. Photo 165 7. Apply pressure to the left hand side plunger pin by pushing on the steering arm with the palm of your hand and insert a shim between the locking collar and the welded tab stop.
Argo Service Manual Brake System Photo 168 Photo 169 Vehicles manufactured from 22441 i. Remove the (2) Spring Pins and Steering Arms from the Steering Shaft. Photo 169 A Retaining Ring is located between the (2) steering arms. Reassembling Steering Column - Prior to 22441 i. Install the Spring Pin into the Steering Shaft at the 4th hole from the end.
Brake System Argo Service Manual NOTE Please observe the orientation of the free end of the springs. Each is pointing in the same direction as the steering arms. Photo 176 Photo 173 Photo 175 Photo 174 Photo 176 Vehicles manufactured from 22441 i. Install the Spring Pin at the 2nd hole from the end on the Steering Shaft. The roll pin should be installed such that the slot of the pin is parallel to the shaft, and an equal amount of pin protrudes on each side of the shaft.
Argo Service Manual Brake System iii. Next, install a Retaining Ring to the machined groove on the Steering Shaft. This retaining ring will be located between the 2 steering arms. iv. Install the second steering arm and last spring pin. Photo 178. Orient as in Photo 179 Photo 178 Photo 179 9. Apply some axle grease to the length of the Steering Shaft, Photo ST-180, and insert it from the bottom up, into the Steering Column Assembly with the small keyway facing towards you.
Brake System Argo Service Manual Photo 182 Photo 183 Photo 184 12. Install a Flat Washer and a new 117-29 Nylon Locknut to the threaded end of the steering shaft. Photo 185 13. Tighten down the Nylon Locknut snug. Back off the Locknut just enough to allow the Flat Washer below to be turned by hand. Do not overtighten. Ensure the shaft turns freely with minimal end play. Photo 186 Photo 185 Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421 BR-76 Photo 186 www.
Argo Service Manual Brake System 14. Set the Handle Bar assembly into place and cover with the Upper Handle Bar Clamp. The Handle Bar clamp is secured into place with (4) fasteners. Tighten down the fasteners in an "X" pattern indifferent to starting location at a torque specification of 10 - 12 Ft. LBS (13.5 - 16N.m) Photo 187 Photo 187 15. Apply firm pressure to handle bars in each steering direction to seat the roll pins. 16.
Brake System Ontario Drive & Gear Limited PH.(519)- 662-2840 FAX (519)- 662-2421 Argo Service Manual BR-78 www.argoutv.
