Join Date: Oct 2009
Location: Yarm, Teesside, England
Rear brake disc replacement.
This week after years (?) of cowbells all over Europe I finally bit the bullet and got an EBC disc from Motorworks UK; after taking off the wheel, brake caliper and disc I checked the new one against the wheel and the bevel box, and also against the old one and no problems found. I had to move the ABS rotor over so first get the three small screws out. They take a 1.5mm Allen key which is pretty small and can't take too much pressure without rounding off the hex hole in the screws, so gave it a good lot of direct heat from a small propane torch, then quite hard hammeing on the Allen key to free them alal the while trying to get them loose, finally using a glove to save my fingers from heat and pressure they all came loose one by one. I gave the rotor a good lot of heat and then it levered up ok using a big screwdriver eventually coming off easily. After a clean up the ABS disc including filing off burrs from the levering off, it went on the new disc using a hammer on a solid piece of 2x3 timber, new screws that EBC enclose with the disc went in with thread fixer and then put the disc back on the bevel box. I used the same brake pads which were had plenty of life left, over 4mm, after smoothing their brake surface on an emery cloth on the bench.
I looked for all ways to use the "old" disc by fitting some sort of spring to stop it rattling, but not enough meat in the disc to drill and tap for bolt fixings; the disc was down to near the minimum wear in the Clymer manual, 6.5mm, and flats on the pins. So paid up the £180+ and did the full job. Just need a better than average UK day in November (ie a dry sunny one) to try it out but don't see any problems arising. Best to keep this class of bike in cOrrect condition; when you're 1000,miles from home you need the confidence it's as good as it should be.
Just for info for anyone thinking about this job,