96 TXT DCS brakes Adjustment

RebelStryker

I have a 96 TXT with poor braking. It will come to a stop eventually, but I have to pretty much stand on the pedal. I have the service manual and have tried unsuccessfully to make them work any better. All parts have been cleaned, lubricated, and adjusted per specs. Everything appears to be functioning properly. I have not replaced the pads but they still measure within specs. Are there any tricks?

BGW

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chloe

Assuming your brakes are properly assembled and, as you say, functioning properly, the only real adjustment is the adjustment rod attached to the brake cables. With the pedal in the released position, (up): Go under the cart and find the adjustment rod. Back both nuts off about 1/2 to 3/4 of an inch. Turn the forward most nut "in", (clockwise), until you see some of the slack being taken out of the cables. Rock or push the cart to ensure there is enough drag to barely notice but not so much that it slows the cart. Run the lock nut down to maintain the adjustment. Give the cart a try. Like with automotive drums, you can back the cart up and slam the brake pedal to make minor shoe adjustments with the auto-adjuster inside the drum.

cgtech

I somewhat disagree with post above, i feel adjustment in the drum is more critical than cable adjustment. Heres how: Disconnect brake cables at wheels, grab arm with locking pliers or as i do, slip a small pipe over the arm to use as a lever. Rachet lever untill auto-adjuster (star-wheel) can adjust no more. You can verify adjuster operation by watching it through the hole most drums have. Now reattach cables, if this adjustment process is helping, you will have to adjust (loosen) the brake cables to get them re attached. When all brake adjustments are done by tightening brake cables, the geometry at the arms at the back gets screwy, and cannot get leverage against the brake shoes.

chloe

The problem with that method, cgtech, is that it is not recommended. The instructions that came with my rebuild kit had it and several posts all over the net say the same thing. Scroll down, after the instructions and you'll see the warning.

http://www.ehow.com/how_12081650_adj...golf-cart.html

yurtle

I bought new shoes and star adjusters for my '98 TXT series, and using the instructions in the service manual, am able to completely lock them up at over 36 MPH with four passengers and stock tires. The adjuster to the stars was worn, so it wouldn't auto adjust. I read about someone who had just upgraded to disks here, and bought their backing plate, since EZ-GO doesn't sell the part I needed separately. Larger tires probably take more effort.

The brakes are a system, and have to be adjusted as such, not piece-meal, but having worked on car drum brakes for decades, I knew how they were supposed to work.

One thing that I did was to remove the ridge on the drum with a Dremel. A ridge forms when the shoes wear the drum up to within 1/4" to 1/8" from the edge. This makes removal and re-installation difficult. By doing that, I could adjust the stars where they needed to be, and not too loose to clear the ridge.

sportcoupe

Yurtles instructions come right from ezgo. See attached image. I would go by the manufacture over ehow.com anytime. Oh, it works well too.

Attached Images

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yurtle

Huh?

Lose Belley Fat??

I just did what I said, and it worked. After having rebuilt numerous internal combustion engines, I bought a ridge reamer. Knowing brakes wear the same, I did the same.

yurtle

In my opinion, the EX-GO auto-adjuster is inferior to automobile auto-adjusters. I tried bending the star adjuster, but was unsuccessful. They had to be replaced, and EZ-GO doesn't sell the item separately. Stars are sold, but the star adjuster isn't.

RebelStryker

I have used the service manual procedures and double checked myself several times. I can take all of the slack out of the brake pedal and get slightly more stopping power, but then the parking brake requires two feet to engage. I am leaning towards the auto adjusters not working properly.

Thanks for all the replies!

Golfdog

I have a sneaky feeling that Yamaha G22, G19 and G16 have the same brake components as the EZGO. (in the parts manual they look identical) They list the star adjuster as a separate part #
JN6-F722F-00-00 (RH)
JN6-F722E-00-00 (LH)