Note: Assemble as shown in the figures.
DYNA 150 (with automatic gap adjuster)
DYNA 150 (without automatic gap adjuster)
DYNA 100
1. Assemble the wheel cylinder.
(DYNA 100)
A) Apply lithium-based grease to the cylinder cap and piston.
b) Apply high temperature grease to the adjusting bolt and nut.
V) Assemble the wheel cylinder in the following sequence: cap, piston, boot.
G) Install the adjusting bolt and nut into the cylinder.
- Right wheel cylinder: Left hand thread (Yellow)
- Left wheel cylinder: Right hand thread (White color)
d) Install the regulator lock lever and screw.
(DYNA 150, without automatic gap adjuster)
A) Apply lithium based grease as shown.
b) Apply high temperature grease to the adjusting bolt and nut.
V) Assemble the wheel cylinder in the following sequence: spring, spring seat, cap, piston, two covers.
G) Install the adjusting bolt and nut into the cylinder.
- Right wheel cylinder (FR label): Left hand thread (Yellow)
- Left wheel cylinder (label FL): Right hand thread (White color)
d) Install the regulator lock lever and screw.
(DYNA 150, with automatic gap adjuster)
A) Apply lithium based grease as shown.
b) Apply high temperature grease to the adjusting bolt and nut.
V) Assemble the wheel cylinder in the following sequence: spring, spring seat, cap, boot, wheel cylinder piston assembly and automatic governor lever with spring, adjusting lever retainer, screw.
G) Install the seat and dust seal to the wheel cylinder piston assembly.
d) Install the adjusting nut and bolt to the wheel cylinder piston assembly.
- Right wheel cylinder (R label): Right hand thread (Yellow)
- Left wheel cylinder (label L): Left hand thread (White color
2. Fit the bleed screw as shown.
(DYNA 100 and 150 without automatic gap adjuster)
A) The wheel cylinder fitting sockets on the rear side are flat and tapered in shape, as shown in the figure.
b) Both fitting sockets on the front side of the wheel cylinder are made conical.
(DYNA 150 with automatic gap adjuster)
A) The sockets of the wheel cylinder fitting on the front side are made flat and conical in shape, as shown in the figure.
b) Both sockets of the fitting on the rear side of the wheel cylinder are made conical.
3. (DYNA 100 and 150 without automatic gap adjuster) Install the wheel cylinder on the brake shield.
A) Install the front brake wheel cylinder with the adjuster up and the rear wheel cylinder with the adjuster down.
b) Tighten the wheel cylinder bolts.
Tightening torques:
- DYNA 100 - 18 Nm
- DYNA 150 - 25 Nm
(DYNA 150 with automatic gap adjuster)
A) Install the front brake wheel cylinder with the adjuster down and the rear wheel cylinder with the adjuster up.
b) Tighten the wheel cylinder bolts.
- Tightening torques: 25 Nm
4. Install the brake pipe on the wheel cylinder.
A) Install the brake pipe in place and tighten the nuts by hand, then tighten them with a wrench.
- Tightening torque: 15 Nm
5. Install the brake pipe retainer on the brake shield and tighten with the bolt.
Torque:
- DYNA 100 - 7.4 Nm
- DYNA 150 - 7.8 Nm
6. Apply high temperature grease to the brake pad contact surfaces as shown in the illustration.
7. Install the top shoe (DYNA 100 and 150 without automatic gap adjuster).
A) Install the upper shoe holding the shoe spring, insert the holder and put on the two caps.
b) Install the bottom block in the same way.
V) Using a screwdriver, install the return springs from the front and from the back.
(DYNA 150 with automatic gap adjuster)
A) Bring the shoes to the center so that the return spring hooks on the bottom shoe.
b) Install the brake pads as an assembly.
V) Install the pad retaining spring, insert the holder and put on the two caps.
G) Install return springs from the front and rear.
8. Lightly sand the outer surface of the lining of the shoe and the working surface of the drum with sandpaper.
9. Install the brake drum (DYNA 100) Install the brake drum and tighten the screw.
- Tightening torque: 6.9 Nm
(DYNA 150) Install the brake drum on the hub.
10. Fill the reservoir of the brake system with brake fluid and bleed the brake system.
11. Check for brake fluid leaks.
12. Adjust brake pad clearance.
13. Install the front wheel.