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Scott MacGregor
Plainville, MA 02762
Phone: (508) 695-3717
Fax: (508) 643-0233
Currie Scooter Disk Brake Kit
WARNING:
This kit is designed for installation by experienced bike
or scooter mechanics. It is NOT recommended for any
scooter other than the Schwinn F-18, GT Shockwave
and Mongoose Hornet FS, Flyer SE, and similar Flyer
scooters, nor is it to be
installed or adjusted by anyone
under the age of 18. An
improperly installed or adjusted
brake system can cause
damage to the bike or scooter
as well a injury or death
to the rider or pedestrians! If
you are not experienced
or qualified to install this disk
brake system, bring the
scooter and kit to your local
bike shop for installation.
Kit Parts
Carefully review the parts terminology in the picture
below. You will need to
be familiar with this terminology to complete the steps below.
Click to enlarge
Step 1
Disconnect existing brake actuator cable. Unplug
motor and throttle wiring.
Remove the rear wheel assembly completely.
Click to enlarge
Step 2
Remove brake housing retainer nut from axle. Slide brake housing off of axle.
Click
to enlarge
Step 3
Remove brake drum by unscrewing in a counter-clockwise
direction. I've found
an oil cartridge removal tool works best for this procedure.
Click to enlarge
Step 4
NOTE: Anti-seize
compound has been added to the threads of the adapter.
Also, the six bolts attaching the rotor to the rotor adapter have been torqued
to manufacturers specifications. (see Avid documentation included in the kit)
Do NOT remove or tighten these bolts unless you have the appropriate torque
wrench or you may cause damage to the assembly!
Install new brake rotor and adapter assembly being very careful to avoid cross-
threading. It is not necessary to tighten the rotor more than hand tight.
Thread
the brake housing retainer nut (removed in step 2 above) back onto the axle,
and gently tighten it against the nut already on the axle.
Click to enlarge
Step 5
Slide the caliper bracket onto the axle and
re-install the wheel by tightening
the axle nuts just enough to hold the assembly in place. When installed, the
axle nuts should be loose enough to allow the caliper bracket to be turned but
NOT wobble. If the bracket is too loose, you will not be able to achieve the
proper alignment of the caliper and disk. Accurately
measure the distance
between the outer surface of the rotor disk and the inner surface of the caliper
bracket. (see picture below) This distance must be 17/32" +/- 1/32". If this is
not the case, you will need to add a thin shim to the axle or grind down the
brake housing retaining nut noted in step 2 above.
Step 6
NOTE-1: There are a
variety of brake tab configurations on Currie scooters.
Older models have the tab welded about a 1/2" inboard of the swing arm. The
same tab is nearly directly under the arm on second generation scooters, and
is on top of the arm on current models. You will need to adjust
the installation
information found below to accommodate these differences. Here are a few
pictures of the brake system installed on a late model swing arm. (tab on top)
NOTE-2: The reverse band has
one elongated hole. This hole will attach to the
chassis bracket in a later step. Be sure to insert the torque arm bolt through
the single round hole in this step. Also, be sure the "jog" in the reverse band
angles inward toward the tire.
Position the end of the caliper bracket above the
swing arm of the scooter and
install the torque arm bolt, torque arm stop, reverse band, (using the small
hole)
and finally the washer and nut. Tighten loosely.
Click to enlarge
Step 7
Install the brake tab bolt through the chassis tab and reverse band
using a
washer on EACH side of the tab.
Tighten loosely.
Click to enlarge
Step 8
NOTE: This
step is critical. Be
sure that the caliper bracket is snug between
the frame and inner nut on the axle as you tighten these bolts. Take your time
and be sure that no loads are placed on the caliper bracket as you complete the
steps below, since this can cause misalignment of the caliper with the rotor
disk.
Start by holding the torque arm stop downward against the swing arm. Position
the reverse band as shown in the picture below and tighten the caliper bracket,
reverse band and axle bolts a little at a time making sure that the caliper
bracket is not being bent inward or outward in the process. i.e., the caliper
bracket's torque arm stop should be resting freely
on the scooter's swing arm.
The reverse band (after tightening) should not cause ANY left/right pressure on
this bracket.
F-18 installation
Currie Flyer installation
Step 9
This completes the EVdeals kit portion of the
installation. Final setup of the
Hayes disk brake system is covered in the accompanying Hayes literature.
Be
sure to read and follow the Hayes disk brake installation instructions carefully.
Also, it is advisable to check all hardware for proper tightness and damage
on a regular basis. Torque all hardware to manufacturers specifications and
replace any worn or damaged parts. I have
included a few pictures (below)
that may be of assistance. If you need help or have questions call me at
508-695-3717.
