DR650 Rear Brake Pad Change Help Please!

[andyandtherman]

Hi All,

 

I am trying to change out the rear brake pads on my 2009 DR650 and see that it is a floating caliper system. I removed the rear pin without much trouble, but the front pin is giving me fits! I have no idea how in the world to remove this pin and thus remove the caliper to exchange the pads. Someone on another forum has suggested there's a retaining pin in there that should be reomved instead of the pin, but I can't see that  if it is indeed the correct solution. Any ideas?

 

 

Thanks in advance!!!!!

 

Andy

[kezzajohnson]

From the manual if it's any help.

 

[andyandtherman]

Thanks very much!

[54321]

The manual doesn't really solve your problem and misses lots of little tricks that you need to be aware of.

 

If the pins are STUCK ... leave the caliper mounted in place. Try giving a sharp wrap on your allen wrench when inserted into Allen bolt. Soak with WD40 or other anti- rust/corrosion. 

Wrapping (not TOO HARD) can break corrosion's hold on the pin. Last resort is HEAT. Use with great caution.

You might also try using a breaker bar, but make sure not to damage allen bolt.

 

Once pins are out, pads will want to fall out. Don'l let this happen. Note the Spring clip retainers under pads. DO NOT lose or mis-place these spring steel retainers. Note where they are located and try not to disrupt them, if you do, be sure to put them back in correctly. It can be confusing ... so look first and KNOW where and how they go in.

They hold pads in place and only go in ONE WAY.

 

Clean area with Brake Clean and tooth brush.

 

Be sure to SAVE the Stainless backing plates on your old brake pads. Don't be a fool and throw them away ... many do. Mistake. They keep brakes from squeaking and help dissipate heat.

Fit them to your NEW pads after you have Champhered edges on new pads. (sand down edges)

 

PINS

The Pins will be corroded. Use steel wool or emery cloth, polish them until like new ... or replace them if too funky. Before installing, coat them with Anti-Seize grease or Copper Grease. Next time they will

come out easy and no corrosion will be present. ?

 

Check big slide pin that lives under rubber cover. Should be clean grease there and caliper should move back and forth easily on big pin. Take care of rubber cover.

 

Before installing new pads, pump pedal gently to force caliper piston out a bit. Don't pump piston out too far, but enough to clean it up. Use Brake Fluid and green Scrubby thing. Polish. Work in and out a few times, (releasing some brake fluid to get them back in all the way) Be careful of rubber seal that piston seats into.  Once piston moves free and easy and clean ... you are ready to install new pads.

 

Double check that the spring clips are in correct position. Now depress caliper pistons ALL THE WAY IN, FLUSH. Install pads and insert Pins. Double check positioning of pads onto spring clip retainers.

Spread pads wide. Tighten pins (coated with Anti-Seize) and include little protective cap. Now you are ready to re-install rear wheel.

 

Last step is to flush out ALL old brake fluid. Do not get air in system. Once all old fluid has been exchanged, bleed as normal. then check fluid level, top up.

Your done.

 

Ride new pads gently for first 50 miles or so. DO NOT over heat them, be careful NOT to drag rear brake (many do and don't know it) Use gently at first, always allowing them to cool

After 50 to 100 miles you're good to go.

 

Do this job once a year and no worries.

Edited September 25, 2014 by 54321