Bocchi the Biker's Life 気まぐれバイク旅
After returning from a touring trip in Kyushu, I decided it was time to replace the brake pads on my Grasstracker 250. The bike features a single disc brake, and with the right tools, the replacement process is relatively straightforward.
While an initial investment in tools is necessary, once you have them, you can save on both parts and labor costs. Plus, doing the maintenance yourself deepens your connection with your bike. In this article, I’ll walk you through the brake pad replacement process and share some key tips and precautions. Safety always comes first, so if you’re using this as a reference, please proceed at your own risk!
When to Replace Your Brake Pads
In general, it’s recommended to replace brake pads when their thickness is 2mm or less. However, the wear rate depends on your riding style and environment, so regular inspections are essential.
I decided to replace mine because I noticed the remaining pad thickness had decreased significantly. Additionally, it had been nearly 20,000 kilometers since the last replacement. Continuing to use worn pads could compromise performance, so I opted for a proactive replacement.
Customizing the Suzuki Grasstracker 250: Enhancing Your Touring Experience with Comfortable Modifications Items You’ll Need
For the brake pads, I chose Daytona Red Pads. I first used these as a beginner and found their balance of control and braking power to be ideal. While they’re slightly more expensive, they offer great cost performance and are beginner-friendly, making them my go-to choice.
Replacement Parts
- Brake Pads: Daytona Red Pads for Grass Tracker/BIG BOY (’00–’14)
The listed price was ¥4,400, but I purchased them on Amazon for approximately ¥2,800.
Tools
- Socket Wrench (14mm)
- Torque Wrench
- Needle-nose Pliers
- Flathead Screwdriver
- File
- Nylon Brush
- Optional) Caliper Piston Removal Tool – Not used in this instance, but having one makes the task easier.
- (Optional) Piston Press Tool – Not used in this instance, but having one makes the task easier.
Maintenance Items
- Parts Cleaner (Recommended: Rubber-safe type) – I used chain cleaner as a substitute.
- Silicone Grease
- Brake Pad Grease
- Waterproof Sandpaper (#1000–)
- Shop Rags
Detailed Steps
Step 1: Removing the Brake Caliper
Use a 14mm socket wrench to remove the two hex bolts securing the brake caliper.
A long-handled socket wrench will make it easier to loosen the bolts without much effort.
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Gradually pull the caliper away from the disc.
The caliper may be quite dirty due to brake dust buildup.
Step 2: Removing the Old Brake Pads
Use needle-nose pliers to remove the clip from the pin.
Pull out the pin that secures the brake pads.
Carefully remove the old brake pads.
Step 3: Cleaning the Caliper
Clean off dirt and brake dust with a nylon brush.
Avoid pressing the piston while it’s dirty, as it could damage the oil seals.
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Use a flathead screwdriver and needle-nose pliers to remove the spring pad.
Insert the old brake pad into the caliper and squeeze the brake lever to push the piston outward.
Important: Never push the piston out without something in place to catch it, as it could pop out completely, causing brake fluid to leak.
Clean the caliper with a parts cleaner.
Parts cleaner can potentially deteriorate dust seals and oil seals, so it is recommended to use a parts cleaner designed to prevent rubber degradation. In this case, I used a chain cleaner as a substitute.
Remove rust and dirt from the piston with #1000 waterproof sandpaper.
While I couldn’t remove all the rust, I minimized uneven surfaces enough for safe use. I plan to replace the piston during the next brake pad change.
Step 4: Installing New Brake Pads
Apply silicone grease to the piston.
Silicone grease is highly heat-resistant and helps prevent the hardening and deterioration of oil seals and dust seals.
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Ideally, use a caliper piston removal tool to rotate and coat the piston with oil. However, as I didn’t have one, I applied oil using paper wrapped around the piston.
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Push the piston back in and reinstall the spring pad.
File the edges of the brake pads.
Sharp edges on the brake pads can put excessive stress on the brake disc and potentially cause damage. Smoothing the edges through chamfering helps protect the disc.
Apply brake pad grease to the contact surfaces between the pads and the piston/caliper.
This reduces vibration and noise during braking.
Insert the new brake pads, secure them with the pin, and reattach the clip.
If the piston is stuck, use a piston press tool for assistance.
In my case, I resolved this by using a flathead screwdriver to forcefully widen the gap—a method I don’t recommend.
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Step 5: Reattaching the Brake Caliper
Mount the brake caliper onto the disc and tighten the bolts. Use a torque wrench to fasten them to the specified torque of 39 N•m.
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Squeeze the brake lever a few times to ensure the pads make proper contact with the disc.
That completes the task.
After replacing your brake pads, drive cautiously until the brakes have properly bedded in.
Regularly check the brake fluid and bleed the lines if needed to maintain optimal performance.
Summary
Replacing the brake pads on the Grasstracker 250 is a beginner-friendly task if you have the necessary tools. Although it may feel daunting initially, the sense of accomplishment and cost savings make it worthwhile. Regularly check your pad thickness and replace them once they’re below 2mm to ensure safety.
Every maintenance task is a learning opportunity. With the right tools and practice, you’ll gain confidence and deepen your connection with your bike. Remember, safety always comes first—enjoy your motorcycle life to the fullest!
