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Originally posted by Gn0me
[br]Firstly, i dunno if all the years and models are the same, my bike is an austrlian 96mdl RR250, mc22.
From memory, theres only 2 main bolts on the rear brake + a bleeder and a bolt that holds the pads to the back of the caliper on mine, but i expect they would all be pretty similar.

**NOTE**At all stages you should take care not to get grease/oil on or near the brake disc or the pads, IF you do make sure and clean it off before riding. You wont be using any grease or oil in this process, but i gotta stress that oil and disc brakes dont mix well, and just greasy fingers is worth avoiding.

TOOLS NEEDED:
a large flathead screwdriver with good leverage (i used a lil one with some pliers for leverage cuz my m8 had borrowed most of my tools)

a 1/2"inch or 13mm spanner- (again i actually used a cheap muti-fit thingy not the proper size, but im pretty sure the size will be right)

a pair of strong hands or a brake piston compressing tool which can be bought at most autoshops for around $10. You could easily come up with another way tho..as long as it squashes the piston back in without damaging anything.



Step 1: undo the flathead screw that appears to be holding the pads at the back. Its actually just a little cover and underneath u will find the actual bolt that holds the pads is a hexkey type.

2: loosen (NOT REMOVE) the hex key while the caliper is still bolted.

3: undo and remove the REAR bolt that holds the caliper. *note the front bolt will pivot and can actually be simply slid out without having to undo it after removing the rear.

4: using ur hand, flip the rear of the caliper up towards the front of the bike without actually removing it, and finish undoing the hexbolt that hold the pads and remove the old pads.

5: Compress the piston back into the caliper as far as possible. *Note, u will need strong hands to do this, or u can buy a tool from any autoshop that will compress the brake piston for you for about $10.

6: install the pads(just hanging will do) and lightly put in the bolt that holds them until your sure the piston has been pushed far enough in to allow the new pads to fit, if not compress the piston more and try again cuz it is usually a tight fit.

7: you should be able to fold the caliper back down now, so kinda hold the pads up in the caliper in position and fold the caliper back down. Make sure BOTH SIDES look and feel like they are sitting properly in the assembly, and replace the main rear bolt that holds the caliper, then tighten the other hexbolt and replace the little screw cap thingy and you're done.
 

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I'm stuck at step 1 - I can't get the dam cap to unscrew :mad:. The rest of the procedure is easy. If I keep forcing it I'm afraid I'll damage it.
 

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ezekiel67 said:
I'm stuck at step 1 - I can't get the dam cap to unscrew :mad:. The rest of the procedure is easy. If I keep forcing it I'm afraid I'll damage it.
An impact driver is what you need
 

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K916 said:
ezekiel67 said:
I'm stuck at step 1 - I can't get the dam cap to unscrew :mad:. The rest of the procedure is easy. If I keep forcing it I'm afraid I'll damage it.
An impact driver is what you need
Any particular type or size I should be looking for?
 

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I've had a go using an impact driver with no luck.

If I keep going I'm going to destroy what's left of the cap. I will leave this for a trained professional.
 

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i had trouble undoing mine too but after soaking in sewing machine oil for a couple of days it undid with a normal flat blade
 

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mr epic said:
i had trouble undoing mine too but after soaking in sewing machine oil for a couple of days it undid with a normal flat blade
Did you remove the entire calliper to do this?
 

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If its already destroyed.....just use a screw driver and hammer, place the screw driver on half an edge, facing anti clockwise, give it a sharp quick knock and it should loosen it.
after that, get a new one........

correct screw drivers to begin with will usually help in avoiding these situations
 

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i took mine apart when taking the wheel off to change my sprockets.
then this metal square shaped thing fell out.
looks like it's to assist the brake pads to stay in position
i think i figured out where and how it goes back in.
(so i hope)
 
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