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Habitual Offender
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 Post subject: How to install rear drum brake on gy6
PostPosted: Sun Dec 11, 2016 2:03 pm 
This is a how-to for how to install drum brakes on a gy6, for new engines or swapped gy6 engines that have a weird disc brake setup and you want to convert to drum instead.

I looked for this info a couple years back and didn't find any images or anything. Did a quick search again now and found some discussions around it but no real how-to or images or anything so hopefully this helps someone in the future.

Its a fairly quick and simple operation as long as you know what parts to get. But if you haven't seen what it's supposed to look like, or don't have a brake setup that you can use for comparison, you may not know exactly what's needed or how to assemble it.

You need the following:
1) gy6 rear drum brakes
2) rear drum brake cam
3) rear drum brake cam lever
4) brake spring
5) brake cable (of appropriate length)
6) brake hand lever

Also, possibly:
1) bolt (6mm or 8mm?)
2) larger brake cable pin (12mm?)

You can probably get everything needed for less than $50. I got everything on partsforscooters.com.

Image

With the wheel off it looks like this:

Image

where I drew the red/black box at the top there usually is a metal arm where the brake crable and spring are mounted. On this particular engine it broke off so I've gotta fab something to put there but for now we can pretend it's there and I'll show a pic later of what its supposed to look like...

First, remove this black plug on the rear of where the brakes will be mounted-

Image

Insert the cam into the hole where you just removed the plug-

Image

Image

Slide the cam lever over the cam. This will help to keep the cam from coming out while you install the drum brakes-

Image

Install a bolt loosely into the backside of the arm to attach it. I had a spare lying around that fit. It slides thru a groove in the cam to keep the cam from coming out-

Image

Get your drum brakes out-

Image

The flat ends go over the flat spot in the cam-

Image

Pull the arms apart and install over the flat part of the cam. Once installed it sits flat-

Image

At the bottom of the drum brakes there is a post-

Image

You need to spread the pads over the top of the post. Needle nosed pliers will work. Be careful not to slip off or pinch your fingers-

Image

The pads are now fully installed-

Image

On the backside of the brake, install the brake spring in the hole (you can see that the brake line mounting tab is busted off here)-

Image

Remove the bolt from the cam lever. Slide it out, then rotate it forward so that the nub in the lever sits inside the spring. Reinstall the bolt-

Image

Image

All together-

Image

Get your brake cable out. It has a pin and a nut on the end of it-

Image

Remove the nut, pin, and spring from the cable. Feed the cable thru the brake cable mounting tab on the case, and replace the spring (this picture was taken from a different case without a broken brake cable tab):

Image

Put the pin thru the eyelets in the cam lever. Then feed the threaded-rod end of the cable thru the pin. Screw the nut back onto the end of the cable-

Image

Image

The pin above is the wrong size and is too small for this lever. I'll need to buy a replacement that is larger. I think there are 10mm and 12mm- this must be the 10 and I need to replace it with a 12. Anyway, it should work as-is but for now will be a little loose until replaced...

The nut can be tightened to adjust the brakes as needed- before riding, and again over time as the brakes wear.

The other end of the cable goes into the hole in the hand brake lever and feeds thru the slot for the cable-

Image

Image

That's all there is to it.

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Junior Mint
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 Post subject: Re: How to install rear drum brake on gy6
PostPosted: Thu Jul 13, 2017 3:22 pm 
where can you buy the pins at?


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Habitual Offender
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 Post subject: Re: How to install rear drum brake on gy6
PostPosted: Fri Jul 14, 2017 7:50 pm 
I got everything on partsforscooters.com.

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Shot Caller
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 Post subject: Re: How to install rear drum brake on gy6
PostPosted: Fri Jul 14, 2017 7:54 pm 
appreciate the work joel.
Thank you.

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Habitual Offender
Habitual Offender
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Location: VT
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 Post subject: Re: How to install rear drum brake on gy6
PostPosted: Tue Jul 18, 2017 10:38 am 
Quote:
Join the Little Kings. You are invited.


little kings?

[edit: nm, I'm a little slow getting caught up on my threads...]

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gy6 super stretch
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Yamaha C3


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