The brake disc removed.

Replacing the front brake discs

Both brake discs must be replaced if

• one of them is thinner than 18mm.
• one of them is thinner than 9mm from the thinnest side to the center.
• one of them has a lot of rust on one of the sides. (Rust is caused by you using the brakes too carefully, or there is something wrong with them.)
• one of them has warped.

Disassembly

1. Clean well.
2. Remove the locking pin (5) (push in 4) and 4.
3. Remove the brake pads (2x3).
4. Loosen the two screws for the hand brake and adjust outwards as long as it goes.
5. Unscrew 4x13.
6. Put down the half caliper (1).
7. Remove the hand brake brake pad.
8. Unscrew 2x14 (if they still are there).
9. Pry off the brake disc (2).
10. Remove the other hand brake brake pad.
11. Clean and grease all 4 pistons with a little LHM, clean them with a paper towel and press them (6) all the way in (PROTECTIVE GOGGLES!).

Assembly

1. Assemble in reverse order.
2. Put in new brake pads (also on the hand brakes if necessary).
3. Clean the area where the half caliper shall be mounted and see to that the two O-rings are where they should be (would be best to put in new ones).
4. If 2x14 are gone (snapped off) you have to fasten the brake disc with 3 wheel bolts (to keep it steady) when adjusting the hand brake.
5. Bleed the brakes.

• 2x14 can be difficult to get out. Normally you will get them out a little, but then they will stop. Screw them all the way in and out again many times; they will get a little longer out every time, and finally you will get them out.
Clean the threads and add a little copper paste before you put them back in again.

• If you don't manage to loosen the brake disc, you can try this:
Clean well, and mount the half caliper and the brake pads. Bleed the brakes. Start the engine and put the gear level in 1th gear to make the brake disc start turning. Brake hard. Now hopefully the brake disc will get loose.