How to Change Rear Brake Pads on Triumph Bonneville

by Soul Tech

Helps you change the rear brake pad set on a Triumph Bonneville.

Supplies

  • 1 Brake pad set T2020555
  • 1 Hex Bit set
  • 1 Torque wrench
  • Hot soap water, clean hot water
  • Grease and cleaning liquids
  • Marking paint
  • Instructions

    Step 1

    Put the motorcycle on center stand or paddock stand

    Step 2

    Use 5mm allen key to loosen the pad retaining pins

    Step 3

    Loosen the pad retaining pins by turning anti clockwise

    Step 4

    Loosen the pins but do not remove them yet

    Step 5

    8mm hex bit for removing the mounting bolts ( it could be a normal bolt from manufacturing- I had changed my caliper mounting bracket hence the hex bolt )

    Step 6

    Use the 8mm hex bit and loosen the bolts alternatively

    Step 7

    Loosen the bolts alternatively and remove them.

    Step 8

    Remove the bolts

    Step 9

    Removing the second one

    Step 10

    Twist the caliper against yourself

    Step 11

    Twist the caliper towards yourself and the caliper will come loose

    Step 12

    Removed rear caliper

    Step 13

    Clean the rotor using a rough or medium sand paper with random hand movement ( don't over do this or use extreme force ). Warning- Be extremely careful with your hand.

    Step 14

    Remove the loosened retaining pins

    Step 15

    Pull the second retaining pin out, you may have to push the pads inward of the caliper to get the pins out

    Step 16

    My worn out rear caliper ( slightly over used :-(

    Step 17

    Use hot soap water and clean the caliper

    Step 18

    Push the pistons together inward to clean the caliper. ( Take care not to push one piston at a time, to avoid the other one popping out and fluid to spill, leading to complete fluid line rebuild )

    Step 19

    Use a small flat screwdriver to pop the pad spring upwards

    Step 20

    This is the flat spring that pushes the pad for alignment and retention

    Step 21

    Clean the flat spring thoroughly with cleaning fluid ( I use WD40 )

    Step 22

    Remove the locator post and clean it

    Step 23

    Grease the guide poles

    Step 24

    Clean thoroughly and wait for the caliper to dry. Wipe down and spray very little WD40 to displace water and lubricate the unit. Wipe off extra lubricants and cleaning fluids

    Step 25

    Align the flat spring back ( note the way it goes in - the small hook that retains the flat spring is towards the pistons )

    Step 26

    The two small arrow like upward bends help keep the two pads separate

    Step 27

    Push both pistons together inside as much as you can ( Important - if you push one piston at a time, you risk the other piston popping out of the bore, which leads to full hydraulic fluid loss )

    Step 28

    Use a new pad - shown here is the inside pad

    Step 29

    Keep it in the caliper

    Step 30

    Push it flush onto the pistons

    Step 31

    Align the pad to the pistons as shown

    Step 32

    Hook the second pad in the guide hook

    Step 33

    And rotate it inwards, note the two arrow like hooks of the flat spring should keep this pad towards the outside of caliper

    Step 34

    Clean the retaining pins with a smooth to medium sand paper

    Step 35

    Do this step very gently. Note this step is to clean the hardened salts on the pin and not to remove metal of the pins. After cleaning, rub the surface with grease.

    Step 36

    You need to push the pads to align them to get a through hole so the retaining pins can be guided in

    Step 37

    Retaining pins guided in and ready to be tightened

    Step 38

    Use the 5mm allen and hand tighten to reasonable strength. Don't over tighten, we shall be doing that using a torque wrench after mounting the caliper back on the bracket.

    Step 39

    Hand tighten the retaining pins

    Step 40

    Push the pads aside and relocate the caliper onto the mounting brackets

    Step 41

    Use thread locker on the mounting bolts. ( After cleaning the bolts with cleaning solvent )

    Step 42

    Tighten the bolts alternatively

    Step 43

    Tighten the bolts alternatively until tight with one hand ( do not use your body weight and over tighten these bolts )

    Step 44

    Use nail polish remover and clean off the old torque marking paint

    Step 45

    Clean the paint that marks the torqued bolt

    Step 46

    Rear brakes mounting bolts are torqued at 40Nm and the retaining pins at 18Nm

    Step 47

    Use a torque wrench and gradually torque to 40Nm by moving through 30Nm, 35Nm. ( It is a good habit to torque up gradually, rather than jumping directly into the factory value )

    Step 48

    Reached 40Nm for both mounting bolts

    Step 49

    Start at 15Nm and reach 18Nm for the retaining pins

    Step 50

    Torquing the retaining pins

    Step 51

    After all bolts and pins are torqued, use a bright coloured nail polish to mark the torqued bolts

    Step 52

    Final step, all torqued and marked

    Step 53

    Start the motorcycle and run in gear and press the pedal, the first pedal push will be completely loose. The pads will align as soon as you pump the fluids in the line using the foot pedal.

    Step 54

    Wear a helmet and go for a test ride, for the first 100km the brake pads have not set in correctly, so don't use aggressive braking, ride slow and run in the pads.