How to Change Kawasaki KLR 650 Brake Pads
Changing the brake pads on a Kawasaki KLR650 should be a part of your dual sport bike's regular miantenance schedule.
Watch the video above and follow the steps below to learn how to change the front and rear brake pads on a KLR650 Kawasaki motorcycle.
See the parts diagrams:
Tools and Parts - Kawasaki KLR 650R Brake Pads Change
- 3/8th ratchet
- 8mm, 12mm sockets
- 5mm Allen
- Flat-blade screwdriver
There are different part numbers for the front and rear brakes:
How to Replace Kawasaki KLR650 Rear Brake Pads
Step 1. Remove the bracket near the rear caliper that holds the brake hose in place.
Step 2. Break loose the two pins that hold the pads in place without removing them.
PRO TIP: It's much easier to break these pins loose while the caliper is still attached to the motorcycle.
Step 3. Remove the two bolts that hold the caliper on the motorcycle.
NOTE: This allows you to lift the caliper away from the motorcycle, but be careful because the brake line is still attached.
Step 4. Use a flat-blade screwdriver to spread the pads apart.
NOTE: The point of spreading the pads is to make plenty of room for new pads with thick braking material.
Step 5. Remove the pins broken loose in Step 2, then lift the brake pads out of the caliper.
Step 6. Replace the rear brake pads one at a time, starting with the inboard (side of caliper closest to the wheel of the motorcycle) pad.
NOTE: This pad doesn't have a C-shaped hook. There's a spring in the caliper, so you'll need to push down on the pad while pushing the pins into place.
Step 7. Repeat the same procedure for the outboard pads, then slide the pins through these pads as well.
Step 8. Replace the caliper and tighten the two 12mm bolts removed in Step 3.
Step 9. Tighten the two small Allen screws that secure the brake pads.
Step 10. Replace the bracket that holds the brake line removed in Step 1.
Step 11. Pump the rear brake pedal a couple of times to get the pads to close in a little on the rotors and build pressure in the system.
How to Change KLR650 Front Brake Pads
Step 1. Break loose the two 5mm Allens that run through the brake pads.
PRO TIP: You don't need to remove them yet, but they're easier to get loose while the caliper is still attached to the fork.
Step 2. Remove the 12mm bolts that hold the caliper on the fork.
NOTE: This allows you to lift the caliper away with the brake line still attached.
Step 3. Use a flathead screwdriver to push the pads in and compress the brake pistons.
Step 4. Remove the two Allen screws loosened in Step 1 to enable you to lift out the brake pads.
NOTE: If there's buildup on the pins, use a wire brush to clean them off a bit.
Step 5. Position the inboard pad first, then push against it to line up the holes so you can send the Allen screws through. Then it's the same procedure for the outside pad, with the same C-shaped hook. Run the Allen screw through this outer pad as well and hand-tighten it.
NOTE: The procedure to replace the front brake pads is the same as in Steps 6-7 for the rear brake pads.
Step 6. Reinstall the brake caliper and the 12mm bolts that hold the caliper in place.
Step 7. Tighten the 5mm Allen screws that hold the pads in place.
Step 8. Pump the brake lever a couple of times to build up brake pressure.
Now that you're done with the brake pads, are you ready to change out the brake fluid on your Kawasaki KLR650? Before you do, watch the video below to see how to bleed the brakes on a Kawasaki KLR 650.
