<<<  Click here to download the practical sheet 

IMPORTANT
This operation is on a vital part of your motorcycle. The slightest mistake can be dangerous for your safety. The practical information below is given simply as an indication. We strongly recommend referring to your motorcycle's manual and using a specialist.

Servicing

• Interval : Between 10 000 and 15 000kms (depending on driving style).
• Difficulty : Not easy.
• Time required : 90 minutes for the fastest of us.
• Materials : Box and flat wrenches, grips, thin screwdriver, compressed air gun, rags, protective gloves, new brake pads, DOT 3 or 4 brake fluid, depending on manufacturer (Elf )

A tip : Use a special product for cleaning your brakes before you dismantle them!

Note that every motorcycle has its own specific braking system, and this is just one example.
For the purposes of this demonstration we have chosen a Kawasaki 750 Z roadster.

Inspection

Check your brake pad wear, it is generally considered that when there is less than 2 mm of pad left, they must be changed.

Note : The thinner the lining (worn), the higher the temperature of the brakes… and the calipers heat up quickly (danger !).

Strip-down

Open the brake fluid reservoir to release the pressure when removing the pads and cleaning the pistons.

A tip : Protect your bike's paintwork from brake fluid splashes, by putting a rag over the reservoir. Brake fluid is very corrosive and will eat paint and lacquer !

Remove the caliper with a suitable box wrench, note the position of the pads

Remove the brake pad pins and note the position of the spring which retains and positions the pads.

Cleaning

Clean the pad spring and the pistons with steel wool (0). Beforehand, you will have slightly pushed out the pistons by operating the brake lever or pedal

A tip : If a piston will not push out, clean the first piston and then push on the second piston (still using the brake lever or pedal), after jamming the first one in position with a screwdriver handle or piece of wood).

Refitting

 After lightly greasing them, push the pistons back in and refit the retaining spring.
A tip : Avoid using grips to push the pistons back in, you may damage them (scoring), try to push them in by hand (protective gloves are quite useful for this).

Now position the new pads in the caliper. Carefully clean and lubricate all of the caliper nuts and bolts.

Reposition the caliper on the disc, secure the caliper to the fork, and tighten firmly.

A tip : Clean and grease the caliper fixing bolts… this will make the job easier next time your remove them !

Checks

Pump the fluid, check the level and add fluid if necessary.