Hydraulic brake maintenance

Brakes are the most important parts of any vehicle. For a safe motorcycle operation a sufficient braking force and the correct position of each brake lever are crucial!

WARNING! A PROFESSIONAL SERVICE IS REQUIRED IN CASE, ...

If You don’t have sufficient mechanical knowledge, experience and proper tools. We strongly recommend, that You have any brake service done by Your local service dealer or at the nearest professional motorcycle service center.
If one brake piston in the caliper does not move – it may be damaged.
If any brake fluid leakage is visible.
If any brake lever feels loose, spongy and/or can be compressed completely to the handlebar and it’s not due to an incorrect set of the brake lever’s distance to the handlebar. Full braking power requires, that the brake levers are stiff and can NOT touch the grips during their full compression. Loose brake lever may be caused by some air in the brake hose, caliper or the brake fluid reservoir, which is very dangerous and can lead to an accident very easily! Each individual brake must be able to hold the motorcycle securely, when You push the motorcycle forward or backward.

Table of contents:

Regular brake system check
Brake levers setup
Brake pads exchange
Front and rear brake caliper adjustment

1. Regular brake system check

Follow these steps before and after each ride:

Required tools:

sliding gauge
brake disc cleaner
soft cloth
Torx wrench #T25
hex wrench #5

Each brake pad has a sufficient brake surface thickness at least 0.03” (0.8 mm). For race event a new brake pads are always recommended.
Brake discs are clean, without any contamination, and securely bolted to wheel hubs.
Brake discs surface thickness is at least 0.06”/1.5 mm. Thinner discs may bend easily.
Brake hoses do not have any cracks or deformations, no visible brake fluid leakage.
Brake system works properly, both brakes have sufficient stopping power.
Double check, that all bolts and nuts are securely fastened.
Brake system requires to be checked once a year for the brake fluid levels and purity. However if the motorcycle is ridden extensively, from steep hills and/or with heavy rider (max. 110 lbs or 50 kgs), shorten the service interval in half. Racers often change the brake fluid in their motorcycles before each race to ensure the best possible stopping power.

2. Brake levers setup

Follow these steps to set the brake levers:

Required tools:

hex wrench #2
hex wrench #4

Let the rider sit on the motorcycle with both hands on the handlebar grips and straighten his/her arms, forearms, palms and fingers.
Using the hex wrench #4 or the cross screwdriver (depending on the brake lever model) loosen bolts, holding the brake levers on the handlebar, and set their angle in parallel to the rider’s straightened fingers, then tighten the bolt (5 - 6 Nm).
Using the hex wrench #2 adjust the brake levers’ distance (fingers’ reach) from the handlebar by a small bolt, located inside the levers, to suit the rider’s grip. Set the same distance for left and right brake lever.

3. Brake pads exchange

WARNING!
If the brake surface thickness of any brake pad is below 0.03” (0.8 mm), it’s time to change brake pads. If You hear a wailing sounds during braking, while the brake pads and discs are clean and properly adjusted, it’s very possible, that You already have no brake material on the brake pads at all. Riding with such brake pads will damage the brake discs quickly and may cause an accident!

Follow these steps to change brake pads:

Required tools:

brush with hard plastic bristles
soft cloth
disc brake cleaner
Torx wrench #T15
plier
hex wrench #5

Ensure, that the magnetic kill switch is in OFF position (magnet NOT attached).
Place the motorcycle on a solid and level surface of a mounting stand, so that both wheels are off the ground.
Manually clean any dirt from the suspension fork and front wheel. Do the same with the swingarm, rear wheel, chain, spring-loaded chain tensioner, both brake disc and brake calipers. A brush with hard plastic bristles will be very useful here. Search for the knowledgebase article "Cleaning the motorcycle and adjusting chain tension".
Clean the motorcycle and let the motorcycle dry off completely. You can speed up this process by hand-spinning the wheels and using a soft cloth.
(Only for Tektro brakes): Using the Torx wrench #T15 loosen the retaining bolt from the brake pads and remove it sideways.
(Only for Riderever brakes): Using a plier straighten the bent end of the brake pads’ retaining pin on the inside of the caliper and remove it sideways.
(Only for calipers mounted on adapters): Using the hex wrench #5 loosen and remove 2 side bolts, holding the brake caliper adapter to the suspension fork or swingarm, and move the caliper away.
(Only for front calipers mounted without adapters): Using the hex wrench #5 loosen and remove 2 bolts, holding the brake caliper to the suspension fork or swingarm, and move the caliper away.
Pull out the old brake pads and the spring from the caliper.
Clean the caliper again with a soft cloth and both sides of the brake disc with a suitable disc brake cleaner.
Using a plastic or wooden wedge slowly and carefully spread the brake caliper pistons from each other to make a space for new and thicker brake pads.
Assemble the new brake pads with the spring and slide them into the brake caliper.
(Only for Tektro brakes): Return the retaining bolt to the caliper and using the Torx wrench #T15 tighten it (2 - 3 Nm).
(Only for Riderever brakes): Install new retaining pin to the brake caliper and using a plier bent its inner end, which will secure the brake brake pads’ position in the brake caliper.
Slowly and carefully slide the caliper with new pads onto the brake disc. Prevent hitting the brake pads from the side with the brake disc.
(Only for calipers mounted on adapters): Reinstall 2 side bolts, holding the brake caliper adapter to the suspension fork/swingarm, and using the hex wrench #5 tighten them (8 - 10 Nm).
(Only for front calipers mounted without adapters): Reinstall 2 bolts, holding the brake caliper to the suspension fork/swingarm, and using the hex wrench #5 tighten them (8 - 10 Nm).
Check, whether the whole braking surface of the rear brake pads is in contact with the rear brake disc, when the rear brake lever is pushed. If not, using the hex wrench #5 loosen 2 side bolts, holding the rear brake caliper adapter on the swingarm, and move the rear brake caliper forward or backward to increase the braking surface to its maximum.
Pull the brake lever repeatedly and check, that the new brake pads are centered to the brake disc - they must travel the same distance to the brake disc and touch it at the same time, with their whole braking surface and without any brake disc tilting. If the brake pads do not move accordingly, go to the following chapter to find more information about brake caliper setup.

NOTE:
New pads require about 30-40 full stops to achieve their optimum braking properties. Subsequently You may need to fine adjust the calipers again.

4. Front and rear brake caliper adjustment

If the distance from the side of the brake disc to each brake pad is different, or brake disc even tilts while in contact with the brake pads, the caliper needs to be adjusted.

Follow these steps to adjust brake caliper:

Required tools:

hex wrench #5

Check, whether the front and rear wheel is aligned perfectly in the suspension fork/swingarm. If not, go to the designated motorcycle manual to find more information about the front and rear wheel removal, installation and adjustment.
Rotate both wheels several times and check, whether brake discs are not bent. Even a small lateral throwing of the brake disc may cause an audible „chirping“, signaling, that the brake disc requires alignment (with hand or a special brake disc tool).
Using the hex wrench #5 slightly loosen 2 bolts, holding the brake caliper to the brake caliper adapter - just enough for the caliper to be able to move sideways.
Press and hold the corresponding brake lever firmly.
Using the hex wrench #5 slowly and alternately tighten both bolts (8 - 10 Nm).
Push the brake lever several times and check, that both brake pads travel the same distance to the brake disc, touching it simultaneously, at the same moment and with their whole braking surface, without any tilting. If not, repeat this process once more.

Follow these steps, if the previous approach does not solve the brake caliper asymmetry:

Using the hex wrench #5 loosen the upper bolt, holding the brake caliper to the brake caliper adapter, and the lower one just slightly for the caliper to be able to move sideways just partly.
Center the brake caliper relatively to the brake disc and tighten the upper bolt.
Repeat the previous steps with the lower side of the caliper.
Repeat both previous steps several times, if it’s necessary, until the caliper is centered perfectly on both sides relatively to the brake disc.
Using the hex wrench #5 slowly and alternately tighten both bolts (8 - 10 Nm).
Pull the brake lever several times and check, that both brake pads travel the same distance to the brake disc, touching it simultaneously, at the same moment and with their whole braking surface, without any tilting. If not, repeat this process once more, until the result is perfect.

If Your motorcycle is under warranty, please register it on our website, if You have not already done so:
https://www.kuberg.com/en/bike-registration

If the problem persists, please contact Your dealer or KUBERG customer service (support@kuberg.com). For the fastest possible resolution please send:

VIN of Your motorcycle (it is stamped on the right side of the steering column).
Detailed information on actions taken so far, a few photos and preferably a video.

Rating:

No rating has been done yet.

Only registered users can rate

Hydraulic brake maintenance

Quick Links

Contact Us