Question about 1992 Honda XR 250 R

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Rear brake caliper removal

How do i remove the rear brake caliper from a honda xr250 dirt bike so i can replace the disc brake pads?

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  • Anonymous Mar 30, 2014

    brake on back of my vtx 1800 stuck and overheated the caliper

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Remove the two bolts holding it on

Posted on Nov 29, 2008

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How to replace rear brake pads 2002 softtail ?


If present, remove right saddlebag.
Remove the rear master cylinder reservoir cap. As the pistons are pushed back into the caliper, fluid level may rise more than 1/8 in. (3.2 mm). You may have to remove fluid to allow for this.
Loosen, but do not remove, both pad pins (12 pt/0.25 in.).
Pry the inside pad back. Use steady pressure to prevent scoring the brake disc. Pry between the pad and the brake disc in order to push the caliper pistons back into their bores.
Once the pistons have been fully retracted into their bores, pull pad pins part way until the inside pads drop free. Note the pad's original orientation for replacement purposes.
Install pad with two tabs on the inboard side of the rear caliper.
Install new inside brake pad using the same orientation as the pad previously removed. Curved portion of pad must face upward.
Install pad pins until the pins snap into place with an audible click. Do not fully tighten at this time.
Pump brake pedal lever to move inside pistons out until they contact inside brake pads.
Pry the outside pad back. Pry between the pad and the brake disc in order to push the caliper pistons back into their bores.
Verify that inside pads are captured between brake disc and pistons. Completely remove pad pins to free outside brake pad. Note the pad's original orientation for replacement purposes.
Install new outside brake pad using the same orientation as the pad previously removed. If the inside pad moved during the previous step, reinstall. Curved portion of pad must face upward.
Install both pad pins through holes in inner and outer
brake pads. Tighten to 180-200 in-lbs (20.3-22.6 Nm).

Jun 03, 2014 | 2003 Harley Davidson FXST Softail Standard

1 Answer

How do you replace the rear brake caliper on a 2006 hd sportster


Start with a suitable container placed under the rear caliper brake line banjo fitting to catch any brake fluid that may leak out. NEVER reuse brake fluid. Use only Dot 5 Brake Fluid in a 2006 XLH motorcycle. NEXT remove the banjo bolt and both washers to detach the rear brake line from the brake caliper and throw away the washers, remove the pad pin plug, unscrew and remove the brake pad pin, remove the brake pads, unscrew and remove the caliper bolt pin, slide the brake caliper on the rear bolt pin away from the brake disc as far as possible. THEN with an open end wrench unscrew the mounting bracket bolt pin from the caliper mounting bracket and lift the brake brake caliper straight up and away from the brake disc and the caliper bracket.

LUBRICATING THE REAR CALIPER BOLT PINS AND BOOTS
FIRST apply about 0.4 g of G40M BRAKE GREASE inside the caliper bushing boot and the caliper pin boot and inside the boot lip to prevent sticking between the boots and the bolt pins and insert the mounting bracket bolt pin into the caliper bushing boot.

INSTALLATION
Before installing the caliper ensure that the retainer bracket is properly installed on the mounting bracket, then apply a small amount of LOCTITE 272 THREADLOCKER to the threads of the mounting bracket bolt pin, place the rear caliper assembly onto the mounting bracket and using an open end wrench thread the mounting bracket bolt pin into the caliper mounting bracket and tighten it to 87-130 in-lbs (9.8-14.7 Nm). THEN apply a small amount of LOCTITE 272 THREADLOCKER to the threads of the caliper bolt pin, slide the caliper bolt pin through the front mounting hole in the caliper, carefully insert the bolt pin shaft into the caliper pin boot in the mounting bracket and screw the bolt pin into caliper and tighten it to 15-18 ft-lbs (20.4-24.6 Nm).
NOTE that the brake caliper housing has a positive stop for banjo fitting and so when tightening the banjo bolt into the brake caliper you will need to rotate the banjo fitting clockwise until it contacts the positive stop.
THEN position a new washer onto each side of the hydraulic brake line banjo fitting, insert the banjo bolt through the washers and fitting into the caliper housing and tighten it to 20-25 ft-lbs (27.1-33.9 Nm). THEN insert the brake pads into the caliper with the friction material on the pad towards the brake disc and with the curved portion of the pad fitting into the recessed area of the caliper and the brake pad front mounting tab fitting into its slot in the caliper mounting bracket. THEN press the brake pads tightly up and against the brake pad spring and install the brake pad pin but if the pin does not easily fit in ensure that you are suing the correct brake pads and not two identical pads, that the brake pad spring is oriented correctly, that the brake pad front mounting tabs are properly seated in the slots in the mounting bracket and that the brake pads are correctly pushed tight up against the brake pad spring BEFORE the brake pad pin is installed. AND THEN tighten the brake pad pin to 131-173 in-lbs (14.8-19.6 Nm). THEN install the brake pad pin plug and tighten it to 18-25 in-lbs (2.0-2.9 Nm). THEN with the rear brake master cylinder reservoir in a level position verify the brake fluid level in the reservoir. If necessary and with the bike upright and not resting on its jiffy stand remove the rear brake master cylinder reservoir cap and add sufficient new D.O.T. 5 BRAKE FLUID to the reservoir to cause the fluid to reach the upper fluid level mark, but do not exceed this mark. THEN verify the proper operation of the master cylinder relief port because a plugged or otherwise blocked relief port could cause the brakes to drag or stick on. Do this by pressing against the rear brake caliper to push the caliper piston back into its bore and push brake fluid back through the master cylinder and into the reservoir. THEN pump the brake pedal until the caliper piston pushes the brake pads out against the brake disc and firm pressure is returned to the brake system.THEN turn ignition switch ON and pump the brake pedal to verify correct operation of the brake lamp and test ride the motorcycle at low speed to safely test the brake system. If the brakes feel at all soft or spongy, bleed the system until you get a firm, hard pedal and avoid making hard stops for the first 100 miles (160 km) to allow the new pads to become conditioned to the brake disc.


Replace brake pads at any time the brake pad friction material on either the front or rear caliper is worn to 0.04 in. (1.02 mm) or less above the backing plate and always replace both pads in a caliper as a set.

The minimum brake disc thickness is stamped on the side of the disc and it must be replaced if and when it is badly scored or worn past the minimum thickness. Maximum brake disc lateral runout and warpage is 0.008 in. (0.2 mm) when measured near the outside diameter.

May 21, 2014 | 2004 Harley Davidson XL 883 Sportster

1 Answer

2003 Suzuki VL 1500 Intruder LC REAR DISC RATTLE,HOW DO I REPLACE IT?


Hello Dale, this is an easy job on your bike. Use a flat head screw driver and remove the brake pad cover...it will pop off.
Remove the hairpin type clips off of the ends of the brake pad pins.... Use pliers & pull the brake pad pins out from the front of the rear brake caliper....Clean the rear brake caliper's piston with brake cleaner. Use a rag and wipe it clean...Reinsert the old brake pads into the caliper. Place a pry bar between the brake pads, then push the inner piston into the caliper body, this will allow room to install new pads.... Remove the old brake pads...Coat the brake pad pins and the new brake pads metal back plates with high-temperature grease.

Slip the new brake pads into the rear brake caliper, then push the brake pad pins halfway into the caliper. Slip the spring clips into place between the brake pads and the brake pad pins. Push the brake pad pins completely through the rear brake caliper. Push the hairpin clips back into the brake pad pin tips. Snap the brake pad cover onto the top of the rear brake caliper....

Pump the rear brake pedal until the pedal feels firm, indicating that the brake pads have closed around the brake rotor...No bleeding will be needed because the system was never opened - That's all there is to it...i hope this information is helpful & good luck with your bike.


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Nov 22, 2011 | 2003 Suzuki VL 1500 Intruder LC

1 Answer

I took the rear tire off my 04 honda crf 250 and when I put it back on my brake was locking. I loosened the brake line bolts and some fluid came out so I had to put more fluid in and now the brake...


Hi,
Sounds like a stuck caliper. You have to pull down the entire caliper assembly and remove the caliper drum, dirt and rust might have accumulated in that area. Use a high pressure air to remove the drum by inserting the air nozzle at the fluid inlet. Replace w/ new set of rubber seal on that caliper drum.
Use water w/ laundry soap and #400 sand paper to remove the dirt.
Check and clean also the brake master sleeve dirt also accumulates in that area.
Fully bleed the system after installing it.
Hope that helps you out.

Aug 06, 2011 | 2004 Honda CRF 250 X

1 Answer

How to replace rear brake pads ducati sport 1000


HI FIRST YOU WILL NEED TO PLACE THE MACHINE ON A SUITABLE STAND SO THE WHEEL SPINS FREELY, THIS OPERATION IS BEST DONE FIRST SO YOU KNOW WHEN YOU HAVE COMPLETED THE JOB THE WHEEL SPINS JUST AS FREE AS IT DID BEFORE HAND,
I TAKE IT THE PADS ARE WORN OUT? IF SO YOU WILL NEED TO CHECK THE LEVEL OF THE BRAKE FLUID, WHEN THE PADS ARE WORN OUT THE CALIPER PISTONS ARE ALMOST FULLY OUT, AND AS ARESULT OF THIS THE FLUID LEVEL IS LOW. IF IN YOUR CASE THE PISTON IS OUT ALL THE WAY AND THE FLUID LEVEL IS NOT LOW, YOU MAY HAVE TO REMOVE SOME OF THE FLUID TO ALOWE THE PISTONS TO BE PUSHED BACK HOME FULLY.

REMOVE THE REAR BRAKE CALIPER,CHECK PISTON CONDITION AND REMOVE ANY DIIRT OR RUST BEFORE COMENCING, USING A SCREW DRIVER OR SIMILAR BETWEEN THE OLD PADS SLOWLY FORCE THEM APART PUSHING THE PISTONS BACK INTO THE CALIPER YOU MAY HAVE TO PLAY WITH THEM FROM SIDE TO SIDE TO GET THEM BACK HOME EVENLY, CHECKING THE FLUID LEVEL WHILST DOING THIS, IF FOR ANY REASON THE PISTONS WONT GO HOME ALL THE WAY CHECK THE FLUID LEVEL, IF REMOVING ANY FLUID REMOVE IT FROM THE RESIVOIRE AND NOT THE PRESURE SIDE OF THHE SYSTEM, THESE BIKES SUFFER WITH POOR PERFORMANCE ON REAR MASTER CYLINDER AND THE LOSS OF ANY FLUID ON THE PRESSURE SIDE COULD PROVE TO BE PAINFULL. REMOVE CLIP SECURING PAD PIN SOME CALIPERS HAVE 2 PINS,AND GENTLY TAP THE PIN OUTWARDS TO REMOVE IT, THE PADS WILL THEN BE REMOVED FROM THE CALIPER, REPLACE IN THE SAME ORDER MAKING SURE THE PAD FRICTION MATERIAL IS FACING THE DISC, WHEN YOU HAVE REPLACED THE PADS, REFIT CALIPER CHECKING SECURITY OF BOLTS, AFTERWARDS CHECK FLUID LEVEL AND SLOWLY START TO DEPRESS THE REAR BRAKE, REPEATING THIS UNTIL THE PADS MAKE CONTACT WITH THE DISC CHECKING THE FLUID LEVEL DOES NOT FALL BELOW MIN ALOWING AIR INTO THE SYSTEM, CLEAN OUT TOP OF RUBBER DIAPRAME IN RESIVOIR AND REPLACE THE CAP. CHECK WHEEL SPINS FREELY, RE CHECK YOUR WORK BEFORE TAKING YOUR MACHINE ONTO THE ROAD, EASY JOB FOR A COMPETENT PERSON, ALWAYS RECHECK YOUR WORK.

Oct 25, 2010 | 2006 Ducati Paul Smart 1000 LE

1 Answer

Is it very difficult to replace rear brake pads on a honda vtx 1300r


Personally I have never replaced pads on that particular bike but if it is like most rear disk pads, should not be too bad. I just remove the 2 bolts holding the caliper to the frame. Lift the caliper off enough to slide the pads out. Get a small C-clamp or something so you can gently push the caliper piston back in. Then install the new pads and bolt the caliper back on. Be carefull when pressing the piston back in because is might cause your master cylinder to overflow a bit. Once the pads are on the bike, pump the brake a few times until the pedal gets firm. Should be no need to bleed the system as long as you don't open any brake lines.
Hope this helps!

Aug 26, 2010 | 2005 Honda VTX 1300 R

1 Answer

I have a 1993 harley heritage it is my first


Changing the rear pads is pretty simple. Just take the two caliper retaining bolts out and lift the caliper off the pads and the caliper bracket. You might have to wiggle the caliper just a bit to get it up and off the caliper bracket.

Replace the pads and the anti-rattle hardware in the caliper bracket. Pay particular attention to which way the anti-rattle hdware goes on. Make sure you put the pads in with the fiber side towards the brake disc.

Now, you'll have to press the piston back into the caliper. You can use either a large pair of slip joint pliers or a C-clamp. Cover the caliper with something to protect the paint. Once you get the piston pushed back into the caliper, carefully replace it on the caliper bracket without disturbing the pads. Put a drop of Loctite 242 blue on the threads of the bolts and torque them to 20 foot pounds.

Check the brake fluid level and slowly depress the rear brake pedal until you get a good firm feeling pedal. Make sure the brakes work properly before you ride the bike. Improper servicing of the brakes can cause severe injury or death. Make sure you do this right.

Feb 05, 2010 | 1993 Harley Davidson XLH Sportster 883...

1 Answer

How do you change front brake pad on a kmx


same way you do on a car. remove the wheel, take the caliper unit off and replace the pads.

1) Put the bike on a milk crate or a bike jack stand
2) Take off the front wheel, the axle comes off like a large bolt
3) Remove the caliper unit from the disc, probably allen wrenches will be needed or at least metric wrenches
4) The pads will come out with a little of force and removing the retaining springs. Take note of how the springs are attached to the pads and caliper unit. You will have to re-assemble the caliper and pads and springs
5) use a C-Clamp to push the piston back into the caliper unit. After you get the caliper unit off of the bike you'll see what I mean. Probably a 6" c-Clamp will work
6) Check the disc for wear and tear. You might have to replace the disc.
7) put new pads into the caliper and attach springs. Take your time, putting the pad springs back on may be tougher than you think.
8) reassemble the caliper and the disc.
9) Put the wheel back on and squeeze the brake. Remember you used a c-clamp to push the piston all the way back into the caliper unit. Squeezing the brake will force the piston out and push the pads against the disc.
10) Time to TEST DRIVE the bike. Go slow and check for wobble or uneven braking. If needed retighten the caliper unit, just don't over tighten the caliper and strip the threads.

Hope this helps....

Nov 12, 2009 | 2003 kawasaki KX 125

2 Answers

Do I need to remove the rear tire on my 2003 harley davidson softail deuce to replace the brakes?


You do not have to remove the wheel according to the manual, but if you wish to remove the caliper you will need to remove the wheel....There are no caliper mounting bolts on the Deuce, the caliper is mounted through the rear axle. TO change the brake pages loosing the pad retaining bolts (2) then push the caliper gently towards the rotor and then pull it gently away from the rotor. This will free up enough space to get the new pads in. Remove the pad retention bolts and replace pads and tighten everything down.

Jun 13, 2009 | 2003 Harley Davidson FXSTD Softail Deuce

2 Answers

How to fit brake bads


Wow, what a nice simple bike to work on...First remove the bolts that hold the caliper to the fork, should be 2, might only be 1 on a bike that lite.. turn the caliper upside down and you will see how to remove the pads, if they haven't already fallen out . Make sure you have the replacements w/you before attempting this repair...Good luck to you...Tim

May 02, 2009 | 2006 Honda CBR 125 R

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