How to change the brake pads on a hyosung GT 250r motorcycle

Written by chris gilliland Google
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How to change the brake pads on a hyosung GT 250r motorcycle
Replacing your Hyosung GT 250R's brake pads yourself is a simple task that will save you money. (roue de moto image by cris13 from

Replacing the brake pads on a Hyosung GT250R is a basic maintenance task that can be done in the comfort of your own garage, saving you the money that would otherwise be spent at your local Hyosung dealer. In fact, even the least mechanically inclined rider can replace the worn-out brake pads with a good set of metric sockets and a few other tools. Once you've done the job a few times, you'll never want to pay someone else to do it for you again.

Skill level:

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Things you need

  • Phillips screwdriver
  • Hex socket set, metric
  • Allen socket set, metric
  • Socket wrench
  • Wrench set
  • Bungee cord
  • Flat screwdriver
  • Replacement brake pads (Hyosung Part #59301HP9500)
  • Brake-cleaning spray
  • Towels

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  1. 1

    Remove the lid from the front-brake master cylinder on the right handlebar, using a Phillips screwdriver to remove the pair of bolts that secure the lid. Pull the lift off the master cylinder and set it aside. This will allow pressure built up within the brake system to vent.

  2. 2

    Using a hex socket, remove the hose hook bolt from the brake caliper and pull the brake hose away from the front fork. Loosen the caliper's mounting bolts with an Allen socket. Locate the pair of Allen-head caliper pins on the outer face of the caliper and loosen them with an Allen socket. Remove the caliper's mounting locknuts on the rear of the caliper's mounting bracket with a wrench.

  3. 3

    Remove the caliper-mounting bolts using an Allen socket and pull the brake caliper away from the front brake rotor. Support the caliper with a bungee cord to prevent damaging the brake hose.

  4. 4

    Pull the caliper's mounting bracket away from the brake caliper. Apply a liberal coat of brake cleaner spray to the bracket and wipe with a clean shop towel.

  5. 5

    Using an Allen socket, remove the pair of caliper pins from the brake caliper. Pull out the brake pads and the anti-rattle spring clip. Pull the anti-rattle spring clip off the brake pads. Slip the anti-rattle spring clip between the set of new brake pads.

  6. 6

    Spray the caliper and its inner pistons with brake cleaner and wipe dry with a clean shop towel. Using a flat screwdriver, press the inner pistons into the caliper. Slip the new brake pads and anti-rattle spring clip into the brake caliper. Insert the caliper pins into the brake caliper and through the brake pad's mounting holes before tightening the pins with an Allen socket.

  7. 7

    Place the brake caliper onto its mounting bracket and tighten the locknuts with a wrench. Slide the caliper over the front-brake rotor and align the caliper's mounting bracket with the front fork. Insert and tighten the caliper-mounting bolts with an Allen socket. Mount the brake hose hook on the caliper's mounting bracket and tighten its bolt with a hex socket. Slip the brake hose under the hook.

  8. 8

    Repeat on the remaining front brake caliper. Once the brake pads have been replaced and the brake calipers reinstalled onto the front fork, prime the brake system by pulling the brake lever in repeatedly. This will rebuild hydraulic pressure within the brake system as the brake caliper's pistons extend and press the brake pads against the brake rotors. Stop when the brake lever requires a firm pull to actuate the brakes. Replace the master cylinder's lid and tighten the pair of bolts with a Phillips screwdriver.

  9. 9

    Access the rear brake pads by locating the rear-brake caliper, which is mounted on the right side of the rear wheel by a bracket attached to the rear swing arm. Unscrew the reservoir lid from the rear-brake master cylinder, twisting it counterclockwise until the lip can be pulled away from the master cylinder. Follow the steps listed above to remove the caliper from the swing arm and replace the brake pads.

  10. 10

    Prime the rear-brake system by pressing down on the brake pedal repeatedly, rebuilding hydraulic pressure as the brake caliper's pistons press the brake pads against the brake rotor. Stop when the brake pedal requires a firm press to actuate the brakes. Screw the reservoir lid back onto the rear-brake master cylinder.

Tips and warnings

  • Take your time. Rushing the job will create problems that will take longer to fix.
  • Don't let the brake calipers hang by their hoses. The weight of the calipers could damage the rubber brake hoses and their fittings, creating leaks that create a loss of hydraulic force and reduced braking capabilities.
  • Be sure that the brake pads are completely secured by the caliper pins. A loose brake pad can be caught against the brake rotor and cause the wheel to lock, creating a potentially dangerous loss of control.

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