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Old 04-18-2004, 11:55 AM   #1
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New monthly tech tip: Brake pad and steel braid line installation.

Oil change and rear wheel removal tips can be found in my sig below.

First off, make sure you have all necc. supplies on hand, use recommended brake fluid (DOT3,4,5, whatever is suggested), and make sure you have an ample supply of rags, brake fluid can and will eat any paint or plastic surfaces it encounters.

The good news is brake fluid is water solluable so it cleans right off easily

Special thanks to Faz for letting me photo and work on his sweet superchicken

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Do Your Own Oil Change!

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Last edited by engineboy; 04-25-2004 at 08:23 AM..
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Old 04-18-2004, 12:07 PM   #2
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Im going to cover the brake pad replacment first. If you are not changing the brake lines, do not remove the hoses from the calipers. There is no reason to open the system unless you are changing the lines.

You want to remove the caliper mounting bolts and remove the caliper.

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Do Your Own Oil Change!

Rear Wheel Removal!

Brake Pad and Steel Braid Line Installation!

Replace Your Battery!

ASE Master Tech for 25 years and counting.

Last edited by engineboy; 04-22-2004 at 05:10 PM..
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Old 04-18-2004, 12:09 PM   #3
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Turn the caiper over and inspect for any wetness around the rubber seals. If there is any moisture there, your caliper is most likely leaking and needs rebuilt or replaced.

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Rear Wheel Removal!

Brake Pad and Steel Braid Line Installation!

Replace Your Battery!

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Old 04-18-2004, 12:11 PM   #4
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On most types of brake calipers, there is a small "cap screw" that keeps the pad retaining screw in the caliper, remove this first.

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Rear Wheel Removal!

Brake Pad and Steel Braid Line Installation!

Replace Your Battery!

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Old 04-18-2004, 12:13 PM   #5
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Under that screw is the pad retaining screw. Remove this and then remove the pads. Pay attention to how the anti rattle clip is in the caliper so you can re-install correctly. *edit* There sometimes is an arrow on the anti rattle clip, and it should point up towards the front of the bike. Thanks Kevo for the tip.

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Do Your Own Oil Change!

Rear Wheel Removal!

Brake Pad and Steel Braid Line Installation!

Replace Your Battery!

ASE Master Tech for 25 years and counting.

Last edited by engineboy; 04-22-2004 at 05:05 PM..
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Old 04-18-2004, 12:14 PM   #6
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You should now have the caliper empty, and it most likely is way dirty like this one

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Old 04-18-2004, 12:16 PM   #7
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Now take a rag and some carb cleaner or other de-greaser and clean the area around the pistons and seals. It should look like this when done.

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Old 04-18-2004, 12:17 PM   #8
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Take a flat screw driver and use the OLD brake pads to compress the pistons back into their bores.

If you are not changing the lines and the system still has brake fluid in it, make sure you dont overflow the brake res. on the front master cylinder. You might have to remove some fluid to give the fluid you are now pushing back into the system some room.

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Do Your Own Oil Change!

Rear Wheel Removal!

Brake Pad and Steel Braid Line Installation!

Replace Your Battery!

ASE Master Tech for 25 years and counting.

Last edited by engineboy; 04-22-2004 at 07:12 PM..
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Old 04-18-2004, 12:19 PM   #9
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Now both sets of pistons should be pushed all the way back in like so......

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Rear Wheel Removal!

Brake Pad and Steel Braid Line Installation!

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Old 04-18-2004, 12:20 PM   #10
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Now install the new pads and retainers, dont forget to tighten the pad retaining bolt and cap screw.

You should put a light coat of grease or some sort of lube where-ever the pads touch the caliper. (we didnt do this cause I forgot, and then I read it here in another post...DOH!..Thanks PhaTeLeSS )

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Do Your Own Oil Change!

Rear Wheel Removal!

Brake Pad and Steel Braid Line Installation!

Replace Your Battery!

ASE Master Tech for 25 years and counting.

Last edited by engineboy; 04-22-2004 at 05:18 PM..
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Old 04-18-2004, 12:24 PM   #11
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Re-install caliper and pump the brakes till you have a firm feel in the lever. I usually use a light coat of loktite blue or red on the threads of the mounting bolts, just a little will allow you to remove if needed at a later date.

If you are not doing lines you are done, make sure the fluid is full and enjoy the new brakes.

If you are doing lines, move onto the following steps.

First remove the lines from the calipers and let the fluid all drain out into a pan of some sort. Do this on both sides.

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Do Your Own Oil Change!

Rear Wheel Removal!

Brake Pad and Steel Braid Line Installation!

Replace Your Battery!

ASE Master Tech for 25 years and counting.

Last edited by engineboy; 04-18-2004 at 01:17 PM..
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Old 04-18-2004, 12:26 PM   #12
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Keep track of all hardware. There will be 2 small copper or aluminum washers for each end of the brake line. The new lines usually come with new washers, but just in case keep all your parts till the job is done.

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Do Your Own Oil Change!

Rear Wheel Removal!

Brake Pad and Steel Braid Line Installation!

Replace Your Battery!

ASE Master Tech for 25 years and counting.
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Old 04-18-2004, 12:30 PM   #13
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Now remove any mounting hardware or brakets that hold the old lines on the bike. There will usually be a braket on each fork, and at least one up inside the fairing holding the left side line.

Now put an old rag under the master cylinder up top and remove the old lines from the master cylinder. This will leak a little fluid so be ready for some possible damage control

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Do Your Own Oil Change!

Rear Wheel Removal!

Brake Pad and Steel Braid Line Installation!

Replace Your Battery!

ASE Master Tech for 25 years and counting.
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Old 04-18-2004, 12:31 PM   #14
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Take the lines out of the bike carefully so you dont throw fluid all over the place, and place them on the ground. You will need to remove the old brakets from the old lines to use them again.

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Do Your Own Oil Change!

Rear Wheel Removal!

Brake Pad and Steel Braid Line Installation!

Replace Your Battery!

ASE Master Tech for 25 years and counting.
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Old 04-18-2004, 12:36 PM   #15
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Now take out the new lines and check them out.

There will be 2 slightly angled ends that go on the caliper side, and usually a straight and angled end on the master cylinder side. Basically the lines will be the same except for 1 end. That straight end goes to the master as seen in the pic below.

The longer line goes to the left side caliper. (as sitting on the bike)

This is what you want the lines to look like at the top, make sure you have all the washers in the correct places.

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Do Your Own Oil Change!

Rear Wheel Removal!

Brake Pad and Steel Braid Line Installation!

Replace Your Battery!

ASE Master Tech for 25 years and counting.
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