Front Brake Pad Replacement

See Brake Pad Lookup to ensure a brake pad match.

Warning:

Avoid touching the pad and rotor surfaces with sharp tools and anything dirty or greasy. Avoid applying one-sided pressure to the rotor.

2013-2014 S-platform

Actual bike used was a 2014 SR (Nissin 313mm). Likely applicable to S/DS/DSR.

Tools

• 13mm hex socket
• Torque wrench
• 4mm Allen key
• Size 1 flat head screwdriver
• Sandpaper
• Brake cleaner
• Ceramic grease (copper grease can interfer with the ABS sensors)

Nissin front brake 2014SR loosen bolts

Nissin front caliper bolts 13mm hex 2014SR

Steps

1. Clean the slave cylinder to prevent forcing damaging detritus into the seal.
2. Gently force the brake pads away from the disk, to ensure room for the new pads, which will be thicker than the worn pads.

   Apply pressure evenly by hand or with a soft-surfaced tool.

3. Pre-2015: Using the Size 1 flat blade screwdriver, remove the cap to expose the head of the pin.

   Warning:

   Penetrating oil may be necessary, and it's important to use the right size flat blade, as smaller ones can strip the slot as you apply pressure.

   Warning:

   Rely on the caliper bolts' anchoring to the disc to ensure leverage.

4. Remove the pin using a 4mm Allen key.

   Warning:

   Rely on the caliper bolts' anchoring to the disc to ensure leverage.

5. Remove the 13mm hex bolts holding the caliper to the fork bracket.
6. Remove the caliper from the brake disc; inspect and clean.

   It may be possible to change the brake pads without removing the calipers from the disk, but removal is more thorough to check for wear and keep it clean.

7. Remove the plate with the brake pads, inspect and clean, and put in fresh pads.
8. Apply ceramic grease to the slave cylinders and sand the front surface of the pads.
9. Re-install the pin through the brake pads to anchor them in place.

   Apply a drop of blue Loctite to prevent it coming loose.

10. Re-install the calipers against the rotor:
    1. With the pads separated sufficiently, slide the caliper over the front disc.
    2. Align the caliper mounting holes with the fork bracket and thread the 13mm hex bolts to hold in place.
    3. Apply some blue Loctite to each caliper mounting bolt and tighten with the 13mm hex socket to the right torque (2014+: 19ft-lb, 2013: 12ft-lb).
    4. Pre-2015: Using the Size 1 flat blade screwdriver and a drop of blue Loctite, re-install and tighten the cap over the head of the pin.
11. Squeeze the front brake lever a few times to build up pressure in the hydraulics and press the pads up to the disc.
12. Test the brakes
    1. Rotate the front wheel to check that the caliper doesn't impede the wheel.
    2. Roll the bike and test the brake lever action.
    3. If there are no obvious problems, gear up and slowly ride the bike to test the brakes.
    4. If possible, gradually increase the speed of the braking tests to seat and smooth the pads.
    5. Perform an initially very slow test ride (walking speed up to 25mph), checking brake function and ensuring they are seated and performing adequately.

2015+ S Platform

Actual bike used was a 2016 SR

1. Locate the bolt used to pin the low side of the brake pads.

   Remove the clip on the inside of the bolt.

2. Detach the ABS wire from the brake line, by carefully unclipping the lower three fasteners holding the ABS wire to the brake line.
3. Remove the bolt pinning the pads with a #25 Torx bit.
4. Back out the caliper bolts with a 8mm hex bit on a 12-inch or longer wrench.
5. Remove the caliper from the rotor.
   1. Complelely remove the caliper bolts and slide the caliper as far as possible off the rotor.
   2. With a flat screwdriver about 8-inches long, drop the inside pad out of the caliper.
   3. After the inside pad clears the caliper, remove the caliper.
6. Temporarily hold the old pads against the pistons by loosely replacing the bolt that pins the pads.
7. Fully push back the pistons, by using a C-clamp with at least 2x2-inch opening and 1-inch heads, clamping the old pads to the outside caliper body.
8. Remove the clamp and old pads.
9. Test fit the new pads.
10. Insert the outside pad in the caliper.
11. Hold the caliper against the rotor and insert the inside pad.
12. Re-install the calipers against the rotor:
    1. Position the caliper to insert the caliper bolts, and tighten a little more than finger-tight.
    2. Carefully drive the pad-pinning bolt until it stops, and reinstall the inboard clip.
    3. Remove the caliper bolts one at a time, apply Loctite 242 or equivalent, and retighten.
    4. Torque the caliper bolts to 19 lb-ft (26 Nm).
    5. Re-attach the ABS wire to the brake line (via the 3 clips).
13. Squeeze the front brake lever a few times to build up pressure in the hydraulics and press the pads up to the disc.
14. Test the brakes
    1. Rotate the front wheel to check that the caliper doesn't impede the wheel.
    2. Roll the bike and test the brake lever action.
    3. If there are no obvious problems, gear up and slowly ride the bike to test the brakes.
    4. If possible, gradually increase the speed of the braking tests to seat and smooth the pads.
    5. Perform an initially very slow test ride (walking speed up to 25mph), checking brake function and ensuring they are seated and performing adequately.