| 4 WHEEL DISC BRAKE INSTALLATION GUIDE |
| NON LIFTED AND LIFTED EZGO GOLF CARTS |
1: Lift the cart and place on jack stands, remove all wheel assemblies
2: Remove the tie rods from the spindle arms. Do Not remove tire rods from the steering box.
3: Remove the front hub and spindle assemblies from both sides. Now install the modified
spindles and re-attach the tie rods.
4: Attach the rotors to the front billet hubs with the vanes slopping forward by using the 5/16
button head bolts that are supplied.
5: Install the caliper brackets on to the modified spindles by using the 5/16" flat head bolts and
nylock nuts that are supplied. Install the hub and rotor assemblies on to the spindles (clean
and lubricate the bearing before installing) torq down the spindle castle nut and install the
cotter pin.
6: Install the caliper assemblies on to the caliper bracket and tighten snugly do not over tighten
See FIG #1
7: Remove rear drum brake by removing the cotter pin,castle nut and flat washer, keep the flat
washer you will need later. Remove the backing plate and brake cables this will come out as a
unit NOTE If there is a wave washer between the brake drum and axle bearing do not keep
8: Install the rear caliper brackets to the axle housing bracket so they are facing to the rear of
the cart using the 5/16" flat head bolts and nylock nuts that are supplied.
9: Install rotors on to the rear billet hubs with vanes facing toward the front of cart using the
5/16 button head bolts supplied.
10: Slide spacer and then the billet hub and rotor assemblies onto the axle , do not use the wave
washer push the assemblies until it stops, install the saved axle washer then the castle nut.
Tighten the castle nut to 75 ft lbs torq and reinstall cotter pin.
11: Install caliper as in step 6
12: Double check all nuts and bolts on all bracket tighten as necessary
13: Remove brake torsion spring assembly from under the floorboard on drivers side of the cart by
removing the pivot pin in front of the assembly, set the pin a side you will need it later.
14: Assemble the brake arm into the torsion spring assembly as shown FIG #2
15: Install the master cylinder onto the brake bracket assembly as shown in FIG #3
16: Install the complete master cylinder assembly to the brake pedal pivot arm by inserting the
pivot in thought the front of torsion spring assembly and brake arm pivot. FIG #4 this will
attach assembly the brake pedal. Let the assembly hang at this point.
17: Lay out the front brake lines ( brake lines are tagged for proper location) install front brake
lines to calipers, leave banjo bolts loose for now . Install master cylinder front brake line to
master cylinder route brake line as needed. Install the brake line tee to the master cylinder
brake line and connect the front brake line to the tee.
18: Install rear brake lines, same as in step 17
NOTE
It's important to install brakes lines without any kinks or sharp bends in the runs. The frame
cross rails of your golf cart has factory cut outs that should be used to direct the brake lines
through.
19: Tighten all the brake line fittings
20: Using the self drilling bolts mount the master cylinder assembly to the frame rail. To do this lift
up on the assembly until is on the frame rail, screw in one self drilling bolt now check for
binding if there is no binding insert the other 2 bolts. Be care full not to over tighten, that may
strip the threads
21: Mount the reservoir in the seat compartment on the drivers side of cart to a stand up support
beam. You may have to drill a hole in the support. Route line to master cylinder and install as
per FIG #5 . Supplied spring clamps must be used on the reservoir lines to keep lines from
leaking.
22: USING DOT 3 brake fluid only fill the reservoir, bleed the brakes. BLEEDING INSTRUCTIONS
Do not let reservoir get empty, refill as necessary. Check for leaks and repair as necessary.
Note when bleeding brakes always start at the farthest caliper. If you are not familiar with
hydraulic brake installations or brake bleeding it is highly recommended to have a
qualified mechanic do the installation for you. You should have brakes now if not re-bleed the
system until you do.
24: Re-install the wheels and tires and carefully test drive the cart, Pump the brakes to seat the
brake pads. Check for leaks in the system repair as necessary . If brake pedal seams spongy
there may still be air in the system, re-bleed
25: Use the supplied tie straps to secure brake lines to the frame of the golf cart
2: Remove the tie rods from the spindle arms. Do Not remove tire rods from the steering box.
3: Remove the front hub and spindle assemblies from both sides. Now install the modified
spindles and re-attach the tie rods.
4: Attach the rotors to the front billet hubs with the vanes slopping forward by using the 5/16
button head bolts that are supplied.
5: Install the caliper brackets on to the modified spindles by using the 5/16" flat head bolts and
nylock nuts that are supplied. Install the hub and rotor assemblies on to the spindles (clean
and lubricate the bearing before installing) torq down the spindle castle nut and install the
cotter pin.
6: Install the caliper assemblies on to the caliper bracket and tighten snugly do not over tighten
See FIG #1
7: Remove rear drum brake by removing the cotter pin,castle nut and flat washer, keep the flat
washer you will need later. Remove the backing plate and brake cables this will come out as a
unit NOTE If there is a wave washer between the brake drum and axle bearing do not keep
8: Install the rear caliper brackets to the axle housing bracket so they are facing to the rear of
the cart using the 5/16" flat head bolts and nylock nuts that are supplied.
9: Install rotors on to the rear billet hubs with vanes facing toward the front of cart using the
5/16 button head bolts supplied.
10: Slide spacer and then the billet hub and rotor assemblies onto the axle , do not use the wave
washer push the assemblies until it stops, install the saved axle washer then the castle nut.
Tighten the castle nut to 75 ft lbs torq and reinstall cotter pin.
11: Install caliper as in step 6
12: Double check all nuts and bolts on all bracket tighten as necessary
13: Remove brake torsion spring assembly from under the floorboard on drivers side of the cart by
removing the pivot pin in front of the assembly, set the pin a side you will need it later.
14: Assemble the brake arm into the torsion spring assembly as shown FIG #2
15: Install the master cylinder onto the brake bracket assembly as shown in FIG #3
16: Install the complete master cylinder assembly to the brake pedal pivot arm by inserting the
pivot in thought the front of torsion spring assembly and brake arm pivot. FIG #4 this will
attach assembly the brake pedal. Let the assembly hang at this point.
17: Lay out the front brake lines ( brake lines are tagged for proper location) install front brake
lines to calipers, leave banjo bolts loose for now . Install master cylinder front brake line to
master cylinder route brake line as needed. Install the brake line tee to the master cylinder
brake line and connect the front brake line to the tee.
18: Install rear brake lines, same as in step 17
NOTE
It's important to install brakes lines without any kinks or sharp bends in the runs. The frame
cross rails of your golf cart has factory cut outs that should be used to direct the brake lines
through.
19: Tighten all the brake line fittings
20: Using the self drilling bolts mount the master cylinder assembly to the frame rail. To do this lift
up on the assembly until is on the frame rail, screw in one self drilling bolt now check for
binding if there is no binding insert the other 2 bolts. Be care full not to over tighten, that may
strip the threads
21: Mount the reservoir in the seat compartment on the drivers side of cart to a stand up support
beam. You may have to drill a hole in the support. Route line to master cylinder and install as
per FIG #5 . Supplied spring clamps must be used on the reservoir lines to keep lines from
leaking.
22: USING DOT 3 brake fluid only fill the reservoir, bleed the brakes. BLEEDING INSTRUCTIONS
Do not let reservoir get empty, refill as necessary. Check for leaks and repair as necessary.
Note when bleeding brakes always start at the farthest caliper. If you are not familiar with
hydraulic brake installations or brake bleeding it is highly recommended to have a
qualified mechanic do the installation for you. You should have brakes now if not re-bleed the
system until you do.
24: Re-install the wheels and tires and carefully test drive the cart, Pump the brakes to seat the
brake pads. Check for leaks in the system repair as necessary . If brake pedal seams spongy
there may still be air in the system, re-bleed
25: Use the supplied tie straps to secure brake lines to the frame of the golf cart
It is the responsibility of the person(s) installing any brake component to determine the suitability of the component or brake kit for that particular application and said person(s) assumes all financial liability's caused by or not limited to improper installation of components or brake kits or systems. If you are not sure how to safely install the brake kit or the components you should consult a professional who is familiar with this type of brake kit installation. DO NOT ASSUME ANYTHING. Improperly installed brakes are dangerous. If you are not sure you may obtain additional information and or technical support from us at (909) 554-0054.The use of our technical support does not guarantee proper installation. YOU or the person(s) who does the insulation must know how to properly use this product. It is not possible over the phone or by any other media to understand or foresee all the issues that might arise in your installation of this product. |
| WARNING |
| WARNING ** DO NOT DRIVE ON UNTESTED BRAKES BRAKES MUST BE TESTED AFTER INSTALLATION OR MAINTENANCE * Make sure pedal is firm : Hold firm pressure on pedal for several minutes, it should remain in position without sinking. If pedal sinks toward floor, check system for fluid leaks. DO NOT drive vehicle if pedal does not stay firm or can be pushed to the floor with normal pressure. * At very low speeds (2-5 mph) apply brakes hard several times while turning from full left to full right, repeat several times. Remove the wheels and check that components are not touching, rubbing or leaking. * Carefully examine all brake components, ( calipers) , brake lines and fittings for leaks and interference * Make sure there is no interference with wheels or any suspension components. * Drive vehicle at low speeds making moderate and hard stops. Brakes should feel normal and positive. Again check for leaks and interference. * Do not drive vehicle until corrections are made to any found leaks or component interferences * Always test vehicle in a safe place where there is no danger to or from other people, obstacles or vehicles |