Brakes maintenance
by 'Guardian' (NL)

This is a short explanation including pictures about brakes maintenance, and replacement of wear parts of the Elystar.
As can be seen on the pictures, I've done this work on my carburettor version of the Elystar, but generally spoken, it works the same way on any scooter.

Photo 1
(Front). Removal of the brake caliper.
Remove the marked bolts.

Photo 2
Remove the chrome safety springs from the caliper. Press the ends together by hand in order to do so. Then, slide them away from the caliper.

Photo 3
Here, you'll see the separate parts: two bolts, two chrome safety springs and the two brake shoes.

Photo 4
Clean the old (or new) brake pads at the back, and spray some copper grease onto that side. Make sure, no grease ends up onto the fron of the brake's inside.

Photo 5. Assembling the caliper
After inspection of all parts, you'll probably be able to assemble the whole thing again. In case you install new, thicker pads, you need to press the brake cylinders back into their space. This can quite easily be done by using two (water pipe) pliers. Just carefully press the pliers around the cylinders and use gently force.

Photo 6
Once the brake pads are properly positioned, it's convenient to use a screw driver in order to keep them where they are. Then, place the chrome safety springs back into their positions.
Make sure, that the brake pads are in their opened position! Slide the caliper over the brake disk, and insert the two bolts. Also, make sure no grease gets onto the disk or the pads!
Now, we finished the front brake.

Photo 7
The rear brake is a bit more of a problem, and requires a few more skills and tools.
You not only need the proper bolt driver, but a nut key size 22 and a fitting bolt key as well.

  1. Make sure you stabelize the rear wheel, so it doesn't turn. Push the wheel onto the floor, and press the rear brake.
  2. Unscrew the wheel bolt, just slightly loose.
Then remove the bolts from the brake caliper. Once you have the caliper loosely on the disk, remove the wheel bolt completely and slide the wheel backwards from the axis.

UPDATE October 2006: please, see below!

Photo 9

Photo 10
Once the rear wheel is removed, you need to unscrew the three brake disk bolts. Careful, though! Locktite has been used on these at the factory!
Remove two bolts completely, and one bolt half-way, so the disk can be moved around a bit. Now, the brake caliper can be removed.
Once done, you assemble the brake and wheel in reverse order.

UPDATE October 2006: Following a message from Grim Reaper and short mail exchange with Guardian, here's a recommendation:

Instead of loosening the center bolt unscrew the three 19mm bolts marked by a yellow cross and you don't have to remove the brake disc. This will save alot of time.
If you have a problem getting the wheel past the exhaust you can just unscrew the 2 rear bolts holding the exhaust about 1cm and it should be no problem.
But be careful! When loosening the three bolts, you may inadvertently damage them, causing them to rust (oxidize) eventually.

I sincerely hope this is of use when you decide to replace or clean the brake pads all by yourself. Looking at dealer prices, things appear to be simple: a set of brake pads will cost about 8-12 euros. Now, assembling and de-assembling a wheel will take about one hour...a workshop will charge 45 euros or more for that. See how much you can save?

Guardian