DS3: Brake maintenance and adjustment

Introduction

This lesson marks the start of the practical part of this teaching unit. The focus here is initially on maintaining the brake system of bicycles. This involves dismantling the brake as far as possible in order to clean all moving parts and, if necessary, relubricate the bearings. Once the brakes have been reassembled, they are adjusted again. Pupils use a step-by-step guide that uses pictures and instructions to illustrate the process of this repair task.

Preparations

In order to be able to carry out this lesson, sufficient bicycles must be obtained in advance. In addition, a side-pull brake should be fitted to the bikes in accordance with the instructions. It should be ensured that the students have the necessary tools and any spare parts they may need to carry out the lesson. The instructions should also be printed out in the appropriate number.

Material overview

* Brake pads if necessary
* Brake cables if necessary
* Bowden cable sheaths if necessary

Tool list

* Pliers
* Open-end/ring spanner M8
* Open-end/ring spanner M10
* Paper towels
* Gloves
* Grease/oil

Documents

Working instructions

Step 1: Unhook the brake cable from the brake lever.
To do this, turn the brake adjustment screw until the slots on the brake adjustment screw and the brake lever are aligned. If necessary, pliers can be used to help.

Step 2: Using a little force, pull the brake cable with the Bowden cable housing over the brake adjustment screw and move it towards the brake lever.

Step 3: Pull the brake cable with the Bowden cable housing out of the lug of the brake lever; the opening of the lug is often located on the underside.

Step 4: The brake cable is now unhooked from the brake lever.

Step 5: Loosen the nut at the front of the side-pull brake. Proceed carefully, as the side-pull brake is tensioned by a spring and can spring open.

Step 6: Remove the two arms and the corresponding spacer discs one after the other. Caution: Do not forget the spring tension! Do not pinch your fingers!

Step 7: Remove the two arms and the corresponding spacer discs one after the other. Caution: Do not forget the spring tension! Do not pinch your fingers!

Step 8: The side-pull brake is now
disassembled. The bolt is still screwed to the
fork

Step 9: The spring remains in position. The bolt is greased. Grease the first spacer disc and place it back on the bolt.

Step 10: The left arm of the side-pull brake in the direction of travel is reattached to the bolt.

Step 11: Grease the white plastic spacer disc and replace it on the bolt.

Step 12: The arm on the right in the direction of travel is reattached to the bolt.

Step 13: Grease the outer spacer disc and position it on the bolt.

Step 14: Tighten the self-locking nut again. Take care not to overtighten it, otherwise the arms will no longer be able to move.

Step 15: The side-pull brake is reassembled, but not tensioned.

Step 16: Clamp the spring of the side-pull brake behind the locking pin. If necessary, pliers can be used to help. Caution: Be careful not to pinch your fingers!

Step 17: Hook the brake cable into the lug on the brake lever. If necessary, a little oil can be dripped into the sheath of the Bowden cable to make the brake cable work again.

Step 18: Press the brake lever lightly and hold it in position. Use a little force to move the brake cable with the Bowden cable housing along the slots away from the brake lever and pull it over the brake adjustment screw. Slowly release the brake lever.

Step 19: Position the cap of the Bowden cable cover in the brake adjustment screw.

Step 20: If the position of the brake pads is not correct, loosen the brake pad nut slightly. Align the brake pad by hand and retighten the nut without moving the brake pad.
Tip: If the brake is applied lightly so that the brake pad is pressed against the rim, the brake pad can be properly aligned.

Step 21: When braked, the brake lever should be in approximately the position shown in the illustration. If this is not the case, the brake cable should be adjusted. This can be done using the brake adjustment screw and the brake cable itself.

Step 22: The brake adjustment screws on the brake lever and on the side-pull brake change the distance between the brake pads and the rim.
If the brake adjustment screws are unscrewed, the distance between the brake pads and the rim becomes smaller.

Step 23: The distance between the rim and the brake pads increases accordingly when the brake adjustment screws are screwed in. If the distance between the rim and brake pads is still too great despite the brake adjustment screws being almost completely screwed out, the brake cable must be shortened.

Step 23: To do this, loosen the locking nut on the side-pull brake arm. The brake adjustment screws are screwed in at the centre so that there is still play in both directions (for turning in and out).

Step 25: Now press the brake pads onto the rim by hand and tighten the brake cable with the pliers in the direction of the arrow (white). Tighten the locking nut again. Steps 23 and 24 are best carried out in pairs.

Step 26: As the brake pads are now already in contact with the rim despite the brake not being applied, the brake adjustment screws must be turned in slightly until the distance between the rim and brake pads corresponds to the illustration.

A final function test should first be carried out carefully by hand by lifting the front wheel slightly and turning the wheel. The wheel should rotate freely without dragging. Nevertheless, the brake pads should engage quickly when the brake is applied. If necessary, readjust the brake adjustment screws.

(Changed: 11 Feb 2026) | Kurz-URL:Shortlink: https://uol.de/p107808en

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DS3: Brake maintenance and adjustment

DS3: Brake maintenance and adjustment

Introduction

Preparations

Material overview

Tool list

Documents