How to Replace the Disc Brake Calipers on a Kona Mountain Bike

Kona bicycle company makes a range of dual-suspension and hard-tail mountain bikes, with many of them equipped with disc brakes. Disc brakes use a caliper that clamps down onto the brake drum causing the bicycle to stop. Disc brakes are either hydraulic or cable actuated. Changing a caliper requires detaching the hose or cable; if you're using hydraulic disc brakes, you need to refill the cable once the new caliper is in place.

Things You'll Need

  • Bicycle work stand
  • Replacement caliper
  • Bucket
  • Hydraulic brake fluid
  • Allen wrenches
  • Crescent wrench
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Instructions

  1. Hydraulic System

    • 1

      Place the bicycle onto the bike work stand and clamp it securely. Remove the wheel of the brake caliper to be changed. Kona bicycles use a quick-release to remove the wheel. Pull the lever in the center of the wheel out and turn it counterclockwise until the wheel drops out. Push the brake hinge to loosen the caliper's grip on the drum allowing the wheel to fall out.

    • 2

      Unscrew the two adapter fixing bolt that attach the caliper to the side of the bicycle frame. Use the Allen wrench to remove these bolts. Unscrew the hydraulic hose cable on thew back rear of the caliper. Use the crescent wrench to remove the cable. Use the bucket to collect the hydraulic fluid as it leaks from the hose once removed. Let the hose drain and pull the caliper off the bike frame and from the hose.

    • 3

      Insert the nozzle of the hydraulic fluid bottle into the end of the cable-hose. Place the new caliper onto the bicycle attachment adapter -- where the bolts held the old caliper. Slide the adapter bolts into the caliper and screw the new caliper to the frame.

    • 4

      Squirt the hydraulic fluid into the hose. Quickly attach the cable-hose nut to the caliper and tighten it down with the crescent wrench. Wipe away any fluid that leaked out during the process. Put the wheel back onto the bike, tighten the quick-release to secure into the frame and flip the brake switch back so the calipers will grip the drum.

    • 5

      Adjust the brake tightness by turning the adjuster barrel on the handlebar one-quarter turn to the right until the desired brake tension is reached.

    Cable System

    • 6

      Place the bicycle into the work stand and remove the wheel. Flip the caliper lever so the caliper releases the drum allowing the wheel to fall out. Unscrew, using the Allen wrench, the attachment adapter bolts so the caliper comes off the frame.

    • 7

      Unscrew the set-screw that holds the brake cable on the upper back portion of the caliper. Pull the caliper off and place the new caliper onto the frame adapter. Screw the attachment adapter bolts onto the caliper to secure it to the frame.

    • 8

      Thread the cable into the set-screw on the new caliper. Tighten the set-screw to secure it to the caliper. Place the wheel back into the bicycle frame. Flip the caliper lever to allow the caliper to grip the drum.

    • 9

      Adjust the brake via the adjuster barrel off the handlebar. Turn the barrel in one-quarter turn increments to the right until the brake is set to your liking.