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Rear brake system rebuild

  • Burrage
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Rear brake system rebuild was created by Burrage

So we are rebuilding, we have replaced the rear brake shoes and are struggling to rebuild. Are there any step by step instructions on how to build brake pedal, rods etc....cheers

Forgot to say it’s  a1973 dt3
Last edit: 16 May 2021 12:09 by Burrage.
16 May 2021 11:47 #1

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Replied by MarkT on topic Rear brake system rebuild

I was just going to ask what bike 

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Anyway... Most are pretty basic so getting your answer will likely be dependent on a description... Or better... Pictures and description... of what you're struggling with.
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
16 May 2021 12:14 #2

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  • Burrage
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Replied by Burrage on topic Rear brake system rebuild

So we are struggling to find the correct position for the cam lever. My son didn’t make anything when he stripped the bike.
We have set it correctly for the brake to operate but the pedal is too high above the foot peg.
how do we adjust the height of the pedal?

We have tried to move the cam lever forward, but when we do this the brake shoes can be heard rubbing, and when we press the brake pedal.. the brakes release...the cam itself looks ok ie. not warn.

actually wondering if the pedal has been bent somehow.
Last edit: 16 May 2021 13:30 by Burrage.
16 May 2021 13:19 #3

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Replied by Mothersbaugh on topic Rear brake system rebuild

Would seem to me that you just need to "trial and error" it a while with the spline choice for the brake camshaft lever. Also does the tension bar adjust the length of the rod itself. Or do you need to include the setting of the chain tensioners in the mix as well? Just shooting from the hip, here...
16 May 2021 20:04 #4

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Replied by JayB on topic Rear brake system rebuild

I have not worked on your exact model, but will speak from experience with similar enduros.

On your machine, there is no rear brake pedal height adjustment.  The pedal tops out by hitting the footpeg bracket.  Usually if it is too high, the pedal has been bent.  Heat and force can bend the pedal to its original height.  Sometimes if the original taller rubber footrests are replaced with lower flat metal ones, the pedal seems a little higher.  Pictures would help us to see what is going on.
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17 May 2021 19:01 #5

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Replied by Schu on topic Rear brake system rebuild

Here is a classic example of a bent rear brake pedal that JayB mentioned.
 
Schu

CT175B, CT175C, JT1' JT2' DT360A, GT80B, DT100B, DT125B,
DT175B, DT175C, DT250B, DT400B, Z50, SCR950

Someday, you'll own some Yamahas
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18 May 2021 09:28 #6

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Replied by apex on topic Rear brake system rebuild

And here's one that's may be bent? This is a '71 DT1

 

This one is probably not bent, and this is a '73 DT3.

 

The pedal on my '72 is pressed/formed steel, the one on the DT3 is cast iron, it looks like. The DT3 is a first timer for me, so I'm not 100% sure if there was a change in pedal design in '72 or '73.

Make sure the arm on the brake drum is pointing down, often I see them pointing up after a rebuild and you'll have a tough tome getting things set up properly that way.

Don't forget the Tech Library link up above has links to free Service Manual downloads that will guide you to proper setup.

 
Allrighty Then
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Last edit: 18 May 2021 10:12 by apex.
18 May 2021 10:08 #7

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  • Burrage
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Replied by Burrage on topic Rear brake system rebuild

All, many thanks.. pedal is definitely bent... I started  the reforge process last night .. looking better already ... thanks for all your help guys
18 May 2021 23:09 #8

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