Gen1 Brake Caliper Removal and Installation
Calipers are removed frequently so that wheels may be removed. Calipers also require removal to be inspected and repaired. The rear caliper must be removed to inspect and replace brake pads.

Tools:
6mm allen bit
light wire or string
torque wrench

Front Brake Caliper Removal
1. If the caliper needs to be completely removed from the bike, first refer to Brake Line Removal for instructions on disconnecting ring couplings from the calipers.

2. Loosen front caliper mounting bolts with a 6mm allen tool.

3. Remove the Front caliper mounting bolts. Remove calipers (tip: apply duct tape to the rim to avoid scratching the paint). Hang the calipers from the fender bracket using a piece of light wire or string if the lines are left connected (another tip: Put an old sock over the caliper to prevent it from scraping while it hangs.

DO NOT APPLY THE BRAKE WITH THE CALIPERS REMOVED. THE PISTONS MAY FALL OUT AND HYDRAULIC FLUID WILL LEAK.

Front Brake Caliper Installation
4. If the brake lines are left connected to the calipers while they are removed, fluid pressure within the system will usually cause the caliper pistons to extend a few millimeters. The brake pads will be too close to fit over the rotor. Push the caliper pistons all the way in keeping firm pressure against the edge of the pads. Twist a piece of plywood between the pads to press them apart. They will fully retract after about 30 seconds of constant pressure.

Loosely reinstall the front calipers and caliper bolts using a 6mm hex tool.

Torque the left and right brake caliper mounting bolts to 25 foot lbs.

Reconnect the ring couplings if the caliper was completely removed (Brake Line Removal, steps 14 through 17)

5. Pump the front brake lever to ensure proper pressure is in the system. Test the
brakes before riding the bike.

Rear Brake Caliper Removal
If the caliper needs to be completely removed from the bike, refer to Brake Line Removal for instructions on disconnecting the ring coupling from the caliper.

6. Loosen rear brake caliper mounting bolts using a 6mm hex tool socket.

7. Remove the rear break caliper. Use light gauge wire or string to hang the rear caliper from the swing arm axle slot if the lines are left connected.

Rear Brake Caliper Installation
8. The pistons will often close a few millimeters from the fluid pressure within the system. To fit the pads over the rotor, push the caliper pistons all the way in keeping firm pressure against the edge of the pads. Twist a piece of plywood between the pads to press them apart. They will fully retract after about 30 seconds of constant pressure.

9. Untie the rear brake caliper from the swing arm and install it to the rear brake
caliper mounting plate using a 6mm hex tool.

10. Torque the rear brake caliper mounting bolts to 18 foot lbs.

Reconnect the ring coupling if it was removed (Brake Line Removal, steps 8 and 9).

11. Pump the rear brake pedal to ensure that there is proper brake pressure. Test the brake before operating the bike.

* Last updated by: Rook on 2/3/2018 @ 1:49 PM *

done

Thanks Rook!! My tires need replacing, and this is the first time I've removed the wheels myself.

Got new tires installed during one of our NC mountain road trips, and after riding 8 hours home to FL I found out the shop had barely hand threaded one of the front fork pinch bolts; almost fell out in my hand

OK, a single pinch bolt may not really be that critical, but what else could they have forgotten! ie ... I don't trust shops.

Glad it helped you out extrap. Yeah, you gotta wonder. If you don't wrench yourself, you gotta have a lot of confidence in whatever shop you go to. ...I say confidence, not faith. If I don't know a shop is good, I'd never go there.