Man, you are a geek! Thanks for testing the ZX-6E last issue. I have one and it's great. How do I change my brake pads?
Todd Canavan
Los Angeles, CA
1. Put your bike on its centerstand or a rear stand, and make sure the area around the discs and calipers is clean and dry. Loosen the small screws that hold the metal cover over the pads and remove the caliper from the fork leg. Be careful not to bend the brake hoses more than necessary. Remove the small cover.
2. The pin that holds your brake pads in place is secured with this small R-clip. Using needle nose pliers, remove the clip and pull the pin out from the caliper-you may need to use pliers, but avoid marking the pin. Now take the pads out and mark on the back which caliper and which side each came from.
3. Wear gloves and safety glasses for this next part, and place a pan under the caliper. Using brake cleaner, spray the inside area of the caliper, letting the cleaner drain into the pan. An old toothbrush can be used to scrub the buildup of brake dust from the pistons. Let the caliper dry.
4. Smooth any marks on the pin with fine sandpaper and clean it with brake cleaner. Install the new pads. If the pistons are out too far and the new pads won't fit, temporarily place the old pads in position and pry them apart following step five. With the new pads installed, re-insert the pin and put the R-clip in place.
5. Using a smooth, flat prying tool-this is a tire iron-gently pry the pads apart, pushing the pistons back into the caliper. Monitor the master cylinder level as you work; if fluid goes beyond the full mark, remove some. If any of the pistons are stuck, you need a caliper overhaul with new seals.
6. Mount the caliper and torque the bolts. Replace the metal cover and screws, and repeat the process for the other caliper. Before you ride away, double-check all the fasteners and pump the brake lever a few times to push the pads into place. Break in your new pads according to the manufacturer's recommendations.