Since the pistons go further into the brake calipers as the linings wear, they must be pressed back when installing new, thick linings. In this case, the brake fluid is squeezed out through the pipelines into the expansion tank. If during this period of time the brake fluid was added in vain, then the excess must now be sucked off. Otherwise, the brake fluid protruding from the expansion tank will corrode adjacent varnished parts in the engine compartment. For aspiration, use a completely clean pipette or an old injection syringe - never aspirate liquid with your mouth!
ATE brake lining replacement
ATE brake: dismantling the linings, first step: wring out with a screwdriver (2) mounting spring (1).
ATE brake: Removing the linings, second step: Loosen the sheathed hexagon socket screws (1 and 2) after removing caps.
Third stage: outer lining (3) in ATE brake caliper housing (2) glued, inner lining (1) inserted with metal brackets (arrow) into the inner bore of the brake piston.
The piston in the brake caliper is pressed with a clamp. For protection, we laid a small plank between them. The Lucas brake caliper installed here usually stays fixed at the top.
1. Raise and secure the front of the vehicle.
2. Remove the wheel.
3. Turn the handlebar so that the pads are easily accessible.
4. Remove the fixing springs from the outside on the brake caliper with a screwdriver.
5. Remove the caps on the inside of the brakes.
6. Insert the Allen key into the already visible Allen key of the guide pins and loosen both pins.
7. Remove the fingers, remove the brake caliper housing.
8. Hang the brake caliper housing on the wire on the suspension strut.
9. Remove the pads on the right and left of the brake caliper housing: the inner pad must be removed with the mounting brackets from the brake piston, the outer pad must be peeled off the brake caliper - if necessary, then with force.
10. Press the pistons in the brake caliper with a clamp. To prevent the piston from warping or being damaged, place a small plank on the adjacent ring.
11. Carefully remove the remaining adhesive film on the adjacent surface of the outer pad.
12. Clean the brake caliper, rust should not be, first of all, on the guides.
13. Insert new pads to stick the outer caliper, remove the protective film from the adhesive area.
14. Install the brake caliper.
15. Tighten the guide pins to 25 Nm and put the caps back on.
16. After assembly, be sure to press the brake pedal several times so that the pads lie against the brake discs. Otherwise there will be no braking effect!
17. With new pads - if possible - brake carefully for the first 500 km.
Replacing linings in Lucas brakes
Lucas brake: unscrew only the bottom fixing bolt (2) brake caliper housing. Press the guide pin in the opposite direction. Top mount (1) remains untouched.
Lucas brake: caliper body (2) after loosening the lower fastening, it leans up. overlays (3 and 4) still in guides. Further visible: 1 - heat shield in the brake piston.
1. Raise and secure the front of the vehicle.
2. Remove the wheel.
3. Turn the handlebar so that the pads are easily accessible.
4. Unscrew only the lower fixing bolt of the brake caliper housing, while pressing the guide pin on the hexagon in the opposite direction.
5. Tilt up the brake caliper housing.
6. Take out overlays on the right and at the left from guides.
7. Clamp out the piston in the brake caliper. To prevent the piston from warping or being damaged, place a small plank on the adjacent ring.
8. Track the correct position of the heat-shielding screen in the brake piston.
9. Insert new pads.
10. Mount the brake caliper.
11. Tighten the new one (!) lower fixing bolt 30 Nm. Do not tighten the upper fixing bolt, otherwise the self-locking effect will disappear. Use a narrow open end wrench to push in the opposite direction of the guide pin, otherwise it will jam and distort the tightening torque.
12. After assembly, be sure to press the brake pedal several times so that the pads lie against the brake discs. Otherwise there will be no braking effect!
13. With new pads - if possible - brake carefully for the first 500 km.
Removing the front brake caliper
The front brake calipers are attached to the suspension strut with so-called ribbed bolts. These bolts have a serrated surface behind the hex head to prevent inadvertent loosening of the bolt. These bolts must never be replaced with normal bolts!
Here you can see the brake caliper support (3) with the brake caliper housing removed. in numbers «1» And «2» Brake caliper mounting bolts marked (knurled bolts).
1. Unscrew the wheel.
2. Remove the brake linings with brake calipers (as described in the previous sections).
3. Suspend the brake caliper housing with the brake hose screwed on so that the hose is not taut.
4. Or unscrew the brake hose or tube. In this case, depress the brake pedal and hold it so that the brake fluid does not leak out.
5. Unscrew the fixing bolts of the brake caliper on the brake support.
6. Clean the knurled surfaces of the ribbed bolts before mounting.
7. Tighten the ribbed bolts to 125 Nm.
8. Screw the brake hose or brake pipe back on.
9. Bleed the brake system if the brake hose or brake pipe has been loosened.
10. Before the first meters of movement, depress the brake pedal several times to adjust the normal pedal clearance.
Replacement of cuffs of the brake piston
If the brake piston collar in the caliper is damaged, then you need to take care of replacing it as soon as possible, otherwise the piston will soon jam due to dirt and corrosion. Cuffs are on sale only assembled with a lining ring of the brake piston. To install both parts, you need to squeeze the piston out of the brake caliper. For the sake of safety, this work must be carried out in the workshop. Depending on the circumstances, also dismantle the brake caliper itself and take it in for repair.
Replacing the front brake disc
Brake discs must be changed on both sides at once. One-way replacement may result in uneven braking effect.
1. Completely dismantle the brake caliper as described and secure with wire to the body. The hydraulic hose remains connected.
2. The brake disc can only be removed from the wheel hub by hand.
3. If it is rusted, then help yourself with strong hammer blows, but only if the disk changes.
4. Before installing a new brake disc, clean the adjacent surface on the wheel hub.
Visitor comments