Mythos
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Brake Caliper Removal Gen2 Hayabusa
If you are completely separating the calipers from the bike, you will want to bleed all brake fluid out and disconnect the brake lines from the caliper (see Brake and Clutch Fluid Bleed )before removing the caliper. For most procedures, you can just leave the brake lines connected and hang the caliper on the side of the bike. I usually pull an old gym sock over each caliper while it hangs to prevent scratches.
When the calipers are removed with brake lines connected, be careful to not apply pressure to the brake lever/pedal. This will cause the brake calipers pistons to extend. With no rotor between them, they could pop out.
The calipers fit close to the wheels. It’s inevitable that they will touch the wheel when the calipers are removed. For this reason, I always apply a layer of masking tape or duct tape to the wheel near the calipers before removing the calipers.
Tools and Materials:
masking tape
5mm hex tool
10mm socket
rag
wire
old socks
silicone grease
piece of wood
Rear Brake Caliper Removal
Remove the rear brake line retainer clip (see Brake Line Removal, step 15).
Apply masking tape to the rear wheel above the rear brake caliper to prevent damage to the paint on the wheel.
Use a 5mm hex toolto remove the rear brake pad pin.
2. Use a 10mm socket to remove the rear brake caliper mounting bolt.
3. Pivot the rear brake caliper up until it clears the brake pads.
Pinch the brake pads against the rotor with your fingers so they do not fall out of the brake pad spring.
Slide the rear brake caliper inward off of it’s pivot.
4. Tie a rag around the muffler hanger to protect the finish and use wireto secure the rear brake caliper so it will not hang on the brake line or fall on the floor. Place a rag under the caliper or cover the caliper with an old sockto protect the muffler from scratching.
5. The brake pads can fall out very easily while the rear brake caliper is removed. Take the pads out of the clip and set them aside.
Remove each pad by twisting the bottom tine up out of the spring. Then pull the top tine down and out of the spring.
Rear Brake Caliper Installation
6. Clean the surfaces where the brake pad tines slide in the brake pad springs and apply silicone grease. There is a brake pad spring in the caliper and on the caliper mount.
Install the brake pads using the reverse procedure explained in step 5 of this tutorial.
7. Apply silicone grease to the pin inside the baffle on the rear brake caliper.
8. Apply silicone grease to the pin on the rear caliper bracket.
9. Press the rear brake caliper piston into the caliper with your fingers. You don’t have to apply a tremendous amount of pressure. Use both hands and hold constant pressure for 30 to 60 seconds. You may also twist a piece of 1/4”plywoodin the caliper to press in the piston.
10. Pinch the brake pads against the rotor. Install the rear brake caliper using the reverse procedure described in step 3.
11. Tighten the rear brake caliper mounting bolt with a 10mm socket.
Torque, Rear Brake Caliper Mounting Bolt: 12.5 ft lbs.
12. Tighten the rear brake pad mounting pin with a 5mm hex tool.
Torque, Rear Brake Pad Mounting Pin: 11.0 ft lbs.
13. Pump the rear brake pedal until brake pressure is restored.
Install the rear brake line retainer clip.
Front Brake Caliper Removal
14. Use a 12mm socket to remove the two caliper mounting bolts on each front caliper. Loosen the bolts a little at a time evenly.
15. Place duct tape on the rim behind the caliper. Pull the caliper off of the dowels and twist the pads inside the caliper left to right gently against against the rotor to spread the pads about 1mm. This will allow the enough clearance to remove the caliper from the rotor without contacting the taped surface of the wheel much.
16. Allow the calipers to hang on their lines or tie them to the triple tree to support them. Placing a sock over the caliper is a handy trick to prevent them from scratching other parts while they hang on the bike.
Front Brake Caliper Installation
17. Installation is the reverse procedure of removal.
Press the pistons in as far as possible with your fingers or twist a piece of 1/4 inch plywoodbetween the brake pads. Constant pressure for about 60 seconds will do. It is not necessary to to use a great deal of force.
18. Slide the caliper between the front wheel and the front brake disc.
Slide the front brake pads over the front brake disk placing the caliper onto the dowel pins.
Install the front brake caliper mounting bolts hand tight and then torque them evenly in steps.
Torque, Front Brake Caliper Mounting Bolts: 28 foot lbs
19. Pump the front brake lever until brake pressure is restored.
