F650 Workshop - replacement of braking disk

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After approximately 50 000 kilometres the front and rear braking disk of my F650 needed to be replaced. Both disks were 4.5 mm thick - the factory given limit. Replacing the braking disks should go together with the mounting of new braking pads as well. The old pads can damage the new disks and you don't want that to happen. After the first new pads the old ones can be scoured with waterproof sandpaper and used. Replacement of the braking disks is an easy to do maintenance job: dismounting the wheel - loosen six bolts - put on the new disk - putting back the wheel again. Al together changing the disk and pads takes about one hour per wheel.

Tools: spanners or drive sockets to loosen the front or rear axle, hexagonal tool #4, soldering iron or cigarette lighter.
Extra parts: new braking disk, 6 new bolts, loctite.

  1. Put the bike on the centre stand and let the wheel to work on hang free from the ground. By putting some logs under the crank case the front wheel stays airborne.
  2. Remove the axle and put the wheel on a piece of cardboad. Watch were all the distance washers go.

    The front mudguard can stay in its place, at the rear only the mid part of the grey chainprotector has to be removed.

    If you don't own a torque wrench for the axle torques just make a mark on the nut and end of the axle. Building the lot together you can fasten the axle nut until the marks are together again.

  3. Heat one bolt of the braking disk with use of the soldering iron (the old loctite desintegrates) and remove the bolt. Do so for all six bolts at the disk.

    The bolts are very soft and easy to damage. With a small hacksaw you can make a slitch to loosen the bolt with a screwdriver. Do this very carefully - when the head of the bolt comes off you'll have to drill out the hole! Lengthening of the hexagonal tool as stated in the König repair manual is useless - the bolt is damaged immediately.

  4. Put the new disk on the hub - watch the right direction of the disk. Turn new bolts in with some loctite and at 12Nm torque. Putting loctite beforehand on the other bolts is counterproductive, the glue dries very quickly.

    Meanwhile change the brake pads.

  5. Put some grase on the axle and remount the wheel. Watch that all washers and the speedometre cable come in the right place. The front axle is tightened at 80Nm, the securing nuts at 12Nm. The rear axle is set at 100Nm.
  6. Check if the wheel turns well. The brake pads always make some scouring noise when rotating the wheel.

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meine van essen menk@wanadoo.nl
HomePage v.6.2 - 11 December 99