1: Lift golf cart and place it on jack stands
2: Remove all 4 wheels from cart
3: Remove stock front hubs from spindles and place hubs on work bench for now
4: Remove the rear brake drums, unscrew axle nuts and remove rear hubs
5: Remove rear brake assembly and backing plates
6: Undo the tie rods from the spindle steering arms and remove the front spindles from the cart, To do
this you will need a roll pin tool and a hammer, drive out the roll pins in the spindle do not lose them
you will need them to reassemble spindles. Carefully drive out the king pin take care to note the
sequence of the parts that came off the spindle assembly ( washers, spacers, roll pins ) for
reassembly . See FIG 1
7: Reinstall the spindles with the caliper brackets installed, install the tie rods. FIG 2
8: Carefully remove the front and rear bearings from the stock hubs and note how the
tapered spacer is inserted in the hub, now install the bearings and the spacers into the new
front hubs, install rotors onto hubs. NOTE ALL ROTORS VANES POINT TO THE FRONT OF CART
Install the new hubs and rotors onto the spindles and secure with the spindle nut now install calipers
complete assembly should look like FIG 3
9: Install the rotors onto the rear hubs, install the caliper brackets to the rear axle housing with opening
facing to the rear of cart, slide the supplied axle spacer onto the axle and then the rear hub assembly
on to the axle install axe nut and tighten down the hub. Now install the rear calipers to brackets
10: To install the master cylinder it will be necessary to remove the floor mat and floor access panel,
now remove the brake cable assembly from the cart . Install the master cylinder assembly as shown in
FIG 4 to do this install the master cylinder plate using the self drilling screws that are supplied, install
the brake arm with the slide bushing and bracket as shown in FIG 4, after all connections are made
push brake peddle to check for binding, brake arm must operate smoothly if not adjust bushing until
it does.
11: Install front brake lines now, Note front hole of master cylinder is for the front brake the rear hole is
for the rear brakes. Using a banjo bolt and 2 copper washers install the front brake line into the
master cylinder and then route the brake line through the frame using a self tapping screw attach a
tee to the frames cross bar( center it in the frame cross bar) and install brake line with the 90 degree
fitting FIG 5 route caliper brake lines through the frame to the calipers ( we ran ours behind the
shock supports and down to the calipers so there was no rubbing with the tires) install the
banjo bolts and washers now. Install the rear brake line to the master cylinder and run the line to rear
of cart, install the other tee to the brake line, install the other brake lines to the tee ,short line is for
the drivers side long line is for the passengers side. Install the banjo bolts and washers to the
calipers
12: Install the reservoir and reservoir lines now, Check all brake lines for binding, sharp bends or other
potential problems, correct them. Tighten all brake fittings now. Use a good line wrench on all fittings
13: Using Dot 3 brake fluid fill reservoir and now bleed the brakes. There are many ways to do this if you
are not familiar with hydraulic brakes it is suggested that you consult a professional mechanic to do
this procedure for you.
14: Reinstall all wheels and tires
15: Secure all brake lines to frame or brackets, check for leaks in system repair as necessary , test drive
golf car , if brakes are spongy or not working properly there may still be air in the lines re bleed and
try again after you are satisfied with the installation and all is working properly you can reinstall floor
panel and floor mat
In our installation we removed some of the floor board out for illustrations purposes, you do not need
to do this for your installation. Thank you CMS
2: Remove all 4 wheels from cart
3: Remove stock front hubs from spindles and place hubs on work bench for now
4: Remove the rear brake drums, unscrew axle nuts and remove rear hubs
5: Remove rear brake assembly and backing plates
6: Undo the tie rods from the spindle steering arms and remove the front spindles from the cart, To do
this you will need a roll pin tool and a hammer, drive out the roll pins in the spindle do not lose them
you will need them to reassemble spindles. Carefully drive out the king pin take care to note the
sequence of the parts that came off the spindle assembly ( washers, spacers, roll pins ) for
reassembly . See FIG 1
7: Reinstall the spindles with the caliper brackets installed, install the tie rods. FIG 2
8: Carefully remove the front and rear bearings from the stock hubs and note how the
tapered spacer is inserted in the hub, now install the bearings and the spacers into the new
front hubs, install rotors onto hubs. NOTE ALL ROTORS VANES POINT TO THE FRONT OF CART
Install the new hubs and rotors onto the spindles and secure with the spindle nut now install calipers
complete assembly should look like FIG 3
9: Install the rotors onto the rear hubs, install the caliper brackets to the rear axle housing with opening
facing to the rear of cart, slide the supplied axle spacer onto the axle and then the rear hub assembly
on to the axle install axe nut and tighten down the hub. Now install the rear calipers to brackets
10: To install the master cylinder it will be necessary to remove the floor mat and floor access panel,
now remove the brake cable assembly from the cart . Install the master cylinder assembly as shown in
FIG 4 to do this install the master cylinder plate using the self drilling screws that are supplied, install
the brake arm with the slide bushing and bracket as shown in FIG 4, after all connections are made
push brake peddle to check for binding, brake arm must operate smoothly if not adjust bushing until
it does.
11: Install front brake lines now, Note front hole of master cylinder is for the front brake the rear hole is
for the rear brakes. Using a banjo bolt and 2 copper washers install the front brake line into the
master cylinder and then route the brake line through the frame using a self tapping screw attach a
tee to the frames cross bar( center it in the frame cross bar) and install brake line with the 90 degree
fitting FIG 5 route caliper brake lines through the frame to the calipers ( we ran ours behind the
shock supports and down to the calipers so there was no rubbing with the tires) install the
banjo bolts and washers now. Install the rear brake line to the master cylinder and run the line to rear
of cart, install the other tee to the brake line, install the other brake lines to the tee ,short line is for
the drivers side long line is for the passengers side. Install the banjo bolts and washers to the
calipers
12: Install the reservoir and reservoir lines now, Check all brake lines for binding, sharp bends or other
potential problems, correct them. Tighten all brake fittings now. Use a good line wrench on all fittings
13: Using Dot 3 brake fluid fill reservoir and now bleed the brakes. There are many ways to do this if you
are not familiar with hydraulic brakes it is suggested that you consult a professional mechanic to do
this procedure for you.
14: Reinstall all wheels and tires
15: Secure all brake lines to frame or brackets, check for leaks in system repair as necessary , test drive
golf car , if brakes are spongy or not working properly there may still be air in the lines re bleed and
try again after you are satisfied with the installation and all is working properly you can reinstall floor
panel and floor mat
In our installation we removed some of the floor board out for illustrations purposes, you do not need
to do this for your installation. Thank you CMS
| YAMAHA INSTALLATION GUIDE |
| For tech support contact us M-F 8 am to 5 pm 909 554-0054 |
| We recommend this system should be installed by a mechanically trained professional or someone with hydraulic brake experience. |
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 |