DIY Network

Service Front Brakes: Install New Cable, Install New Brake Shoes From "Classic Rides" episode DCLR-104

Figure A

In the first three segment of this episode, host Kevin Tetz and Harley-Davidson master mechanic Bill "Dunk" Dunkelberger installed a new drive "secondary chain, removed the rear wheel and fender, inspected the primary chain and clutch and installed a new clutch cable and inspected the rear hydraulic brakes and bled the brake system.

In this final segment the front brakes will serviced, which will involve installing a new cable and installing new brake shoes.

When Kevin first test rode the project '65 Harley-Davidson Electra Glide he noticed that a brake cable (figure A) was frayed and worn at the attachment point and the lever hangs in a partially closed position, which can produce wear on the braking system that eventually prematurely wears the brake system out. For this restoration project the cables have to come off to be replaced. Kevin is going to check the drum as well.

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Installing a New Brake Cable and Shoes

• To install a new cable the front wheel must come off. To do this loosen and remove the hub bolt, axle nut and retaining bolts. Be sure to support the wheel while driving the axle off.

• Slide the axle shaft back into place and use a brass pin to separate the brake drum from the wheel (figure B).

• Now you have easy access to the drum. Pull it off and inspect the brake. Since this is a mechanical system there won't be any fluid. The drum is in good shape, but Kevin did find a small chip (figure C) in the brake shoe pads, so they will be replaced.

• To pull the pads loose, release the tension on the spring by folding the shoes inward.

• What's left is the mechanical part of the brakes -- the cam-and-lever system (figure D) that actually applies the outward pressure from the shoes to the inside of the drum.

  Note: The cam-and-lever system could be sticky so you'll need to clean with a spray brake cleaner. Be sure to wear a filter mask and eye protection for protection from the brake dust.

Figure B

Figure C

Figure D

	Figure E
	Figure F
	Figure G
	Figure H

• Apply a small amount of spray lubricant to the mechanical pivot points of the brake system.

• While the shoes are off go ahead and replace the cable. Remove the nut from the clamp and the clevis (figure E), which is the metal bracket used for connecting the cable to the lever.

• Straighten the cable out so you can pull it back through, and then remove the E-clip from the lever.

• Pull the old cable out.

• Now you're ready to cut out the sheathing, which cuts easily using a rotary tool with a cut-off blade (figure F).

• Go ahead and slide the new cable into place. It slips back into the lever, and the lever goes back on the bike. The pin goes back in to secure the lever and cable.

• Slide the new cable onto the sheathing and bring up the adjusting sleeve the same way and thread it up on the cable.

• The bottom end of the cable goes through the receiver tube and mark the cable at the clevis -- and bend it using pliers (figure G). Add the holding clip and install it onto the clevis -- and then tighten it down.

• With the cable in place it's time to reinstall the new brake shoes. Place the springs in there factory location, which means they only go on one way so what you have to do is to put them back on exactly the way you took them off.

• Cock one side up and the other side against the top pivot point (figure H).

• Place the brake drum back on and you're set.

Now that the brake system is upgraded in the next episode Kevin and Dunk move on to the frame, suspension, wheels and tires.

RESOURCES :

Dremel Tools
Website: www.dremel.com

The Eastwood Company

The Eastwood Company is a supplier of automotive-restoration parts, tools and supplies.

The Easthill Group, Inc.
The Eastwood Company
Website: www.eastwoodco.com

Eazyrizer Big Blue Motorcycle Lift (Driven Gear)
Driven Gear Inc.
Website: www.drivengear.com

RaceDeck Modular Flooring (SnapLock Industries)
SnapLock Industries
Website: www.racedeck.com

Restoration Parts (Custom Chrome)
Custom Chrome
Website: www.customchrome.com

CycleDry Compact Motorcycle Dryer (Georgia Cycle Works)
Georgia Cycle Works
Website: www.cycledry.com

GUESTS :

William "Dunk" Dunkelberger
Restoration Coordinator / Mechanic
Harrly Hoggs & Piggletts
1409 Piney Rd.
Maryville, TN 37803
Phone: 865-681-7699
E-mail: hoggsandpiggletts@yahoo.com