STEP 1:
REMOVE WHEEL AND TIRE FROM THE FORK ASSEMBLY. CAREFULLY
CENTER PUNCH EACH OF THE THREE DOME-SHAPED FEATURES ON JUST ONE SIDE OF THE
RIM. NORMALLY, THIS WILL BE ON THE LEFT SIDE, BUT IT CAN MOUNT ON THE
RIGHT SIDE AS WELL.
ALL OF OUR BRAKES ONLY FIT THE AZUSA 8-INCH "SPINNER" RIM, WHICH IS PICTURED HERE. TO CONVERT YOUR FRONT WHEEL FROM 6-INCH TO 8-INCH, SEE THE LINK BELOW.
STEP 2:
USING THE CENTER PUNCHED DIMPLE AS A GUIDE, DRILL A SMALL PILOT HOLE THROUGH EACH OF THE
THREE DOMES USING A 1/8-INCH (3.2mm) DRILL. THIS IS A NECESSARY STEP
IN ORDER TO GET A GOOD ALIGNMENT FOR THE NEXT DRILLING OPERATION.
STEP 3:
DRILL
OUT THE THREE DOME-SHAPED FEATURES USING A 5/16-INCH (8.0mm) DRILL, THEREBY EXPOSING THE EXISTING
HOLES THAT WERE MOLDED INTO THE RIM. VERIFY
YOUR NEWLY-DRILLED HOLES LINE UP WITH THE EXISTING HOLES.
AN OPTION TO THESE FIRST THREE STEPS IS TO DISASSEMBLE THE TWO HALVES OF THE RIM, AND MERELY DRILL THROUGH, FROM THE INSIDE, AT THE LOCATION OF THE THREE HOLES USING A 5/16" DRILL BIT. DO THIS ONLY ON THE SIDE FOR THE BRAKE.
STEP 4:
ATTACH THE HUB ADAPTOR TO THE RIM USING THREE 5/16-18X1˝ STAINLESS BOLTS, AND THREE
5/16-18 STAINLESS NYLOC NUTS. THE NUTS GO
INTO A HEXAGONALLY SHAPED FEATURE ON THE INSIDE OF THE RIM.
TIGHTEN EACH BOLT TO 10 FOOT-POUNDS (120 INCH-POUNDS) OF TORQUE.
STEP 5:
ATTACH
THE DISC ROTOR TO THE HUB ADAPTOR USING SIX 10-32 STAINLESS, SELF-LOCKING SCREWS. BE SURE TO TIGHTEN EACH SCREW TO
ABOUT 42 INCH-POUNDS (3.5 FOOT-POUNDS) OF TORQUE. DO NOT GET ANY
OIL (INCLUDING OIL FROM SKIN) ON THE DISC ROTOR OR CALIPER. CLEAN
DISC ROTOR WITH
BRAKE CLEANER OR EQUIVALENT SOLVENT.
STEP 6:
RE-ASSEMBLE THE WHEEL BY INSERTING
AN AXLE SPACER ON EACH SIDE OF THE WHEEL ASSEMBLY. INSERT
THE AXLE BOLT FROM THE FAR SIDE, THROUGH FORK TUBE AND AXLE SPACER,
RIM, NEAR-SIDE AXLE
SPACER, FORK TUBE, AND FINALLY THE CALIPER BRACKET.
TIGHTEN AXLE NUT JUST ENOUGH TO TAKE OUT ALL ENDPLAY OF THE WHEEL ASSEMBLY
ON THE AXLE.
SIX CHUTER BRAKE MAY HAVE TO MOUNT ON RIGHT-SIDE OF WHEEL, DEPENDING UPON LOCATION OF STEERING LINKAGE.
STEP 7:
PLACE THE CALIPER BEHIND THE CALIPER BRACKET AS SHOWN, WITH THE BRAKE PADS BEING PLACED ON EACH SIDE OF THE DISC ROTOR. USING THE TWO 6mmX16mm SCREWS AND 6mm WASHERS, SECURE THE CALIPER TO THE BRACKET. TORQUE EACH SCREW TO 42 INCH-POUNDS (3.5 FOOT-POUNDS).
STEP 8:
LOOSEN THE TWO CALIPER BRIDGE CLAMPING SCREWS, AND SLIDE THE MAIN CALIPER BODY BACK AND FORTH IN ORDER TO CENTER THE TWO BRAKE PADS ON EACH SIDE OF THE ROTOR. TORQUE THE TWO CLAMPING SCREWS TO 42 INCH-POUNDS (3.5 FOOT-POUNDS). SPIN THE WHEEL TO VERIFY THAT THE ROTOR MOVES WITH THE LEAST AMOUNT OF DRAG AGAINST THE PADS. READJUST, IF NECESSARY.
STEP 9:
INSTALL BRAKE CABLE FROM BRAKE LEVER TO CALIPER. INSERT INNER CABLE INTO CABLE CLAMP, ROTATE CALIPER ARM UP SLIGHTLY UNTIL PADS JUST BARELY TOUCH THE ROTOR. TIGHTEN THE CLAMPING SCREW, AND TEST THE BRAKE BY SQUEEZING THE BRAKE LEVER WHILE SPINNING THE WHEEL. READJUST, IF NECESSARY, AND TORQUE THE CLAMP SCREW TO 42 INCH-POUNDS (3.5 FOOT-POUNDS).
THAT’S IT! YOU NOW HAVE THE MOST EFFICIENT PPC DISC BRAKE ON THE MARKET. AND IT LOOKS GREAT, TOO! THIS ENTIRE DISC BRAKE SYSTEM ADDS ONLY 2.1 POUNDS (0.95 kg) TO YOUR POWERED PARACHUTE. ADD BRAKE-LOK™ TO YOUR EXISTING BRAKE SYSTEM FOR ONLY $5.00. CALL US ABOUT THIS.
ALL SALES ARE FINAL.
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