even the little things - SUCCESS!!

[sstein]

So I figured replacing the bake pads can't be too hard. Well...

I ordered the recommended pads from Beemer Boneyard - "CL A3+ high performance sintered brake pads"

I checked a few youtube videos and my clymer manual. Seemed relatively straight-forward.

After removing the caliper from the disc, I pressed the pads apart as much as possible to press the pistons in and get some space. I removed the pin and the old pads easily. When I fitted the new pads, I was unable to get enough separation to fit the assembly back over the disc. Tried a few times and ended up replacing the old pads so I could ride today.

Any thoughts? Take it to the dealer? Tail between legs? I mean, really, how hard can this be??!!

[vitaminC]

Did you open the brake MC to allow the fluid to get pushed back? If not, there may be too much pressure, which would keep you from pushing the pistons back any further. Just be careful that brake fluid doesn't get on your paint!

[sstein]

I had taken out all 4 screws and loosened the cover. It did take a lot of pressure to push open the pads even just a little. Maybe the reservoir cover has to be totally off?

[rocky2ie]

Hi, did you make sure to clean the pistons with brake cleaner and a toothbrush or similar before trying to push them back, other wise they could be stiff or even jam. Cheers.

[sstein]

No I did not rocky2ie. Could that account for the problem? I hope I did not do damage by attepting to press the dirty pistons in. There was a lot of caked-on crud I noticed. The brakes are working well now, just not as firm as I would like.

To the dealer?

[vitaminC]

My repair manual agrees that the pistons should be cleaned before attempting to push them back in. However, if you were pushing by hand you probably didn't get them in very far anyway. It also suggests that for increased leverage you can place the old pads back in place, then use a screwdriver or other means to lever the pistons back in, again keeping an eye on the fluid level as you're doing this.

Being that the good brake function is quite important, I'd say that if you have any doubt about your ability to do it right then a visit to a shop or bribing a friend is probably a good idea

[echo42kp]

Just wondering how many miles you got out of the old pads

[sstein]

The bike has 19k miles on it, I've had it since 14k. I am not aware of when the pads were changed prior. To be honest, I think that the pads could last longer, since the breaking surface still has about 2 mm thickness. But I am trying to do and learn, so I figured a new pair of pads can't be a bad thing. I bled the brake lines as well today, using the poor man's technique of pumping the lever. I plan to do a full brake fluid exchange with a vacuum device once (if) I get the pads done.

After taking another look at the Clymer, looks like the EVO brakes (which I believe I have on my 02 r) can have the pads changed while the caliper is still mounted on the fork.

May give that a quick try this weekend, although still don't see how I would have enough space to slip in the new pad.

[riceburner]

As said, you need to clean the pistons off before pushing them back, otherwise you can get crud caught under the weather seal.

the best tool for pushing the pistons back in is actually a plumbers adjustable pliers eg:


Use an old pad to protect the surface of the piston and you can squeeze the pistons back in easily. (make sure the other pistons don't pop out of place.... )

[sstein]

Well, just to follow up - I am very pleased with the outcome of my first brake pad change. Using Riceburner's and the others' advice, I first washed the pistons well with a brake cleaning product. The gunk just melted away. I removed some of the brake fluid from the reservoir to avoid spillage, then used a plumber's adjustable plier and a pad to squeeze the pistons back in. After a small amount of resistance, the pistons glided in easily. I then remounted the calipers, and had plenty of room to slip in the new pads. Replaced the pin and the retainer clip. After a few gentle squeezes of the lever, I had firm braking on the front end.

Rear brake pad change tomorrow - need to get some more cleaner.

Very satisfying day.

I appreciate the advice from the forum and urge anyone who has considered this procedure, but then thought it too difficult, to give it a try.