Finally had a brake warning alert - K-Bikes.com - Excellence in Motion
 
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post #1 of 2 (permalink) Old Jun 26th, 2011, 11:29 am Thread Starter
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Finally had a brake warning alert

The brake warning light came on and with over 46000 miles I figured the brake pads had finally worn down enough to wear through the sensor wire. Checked the front and rear brake pads and they had plenty of wear left. I did a continuity check on the sensor wires and rear pad passed but the front pad failed. I removed the cable ties and felt for a break down the length of the front sensor cable and found a weak spot where the cable had been flexing. Opened it up and found one of the wires broken and the other wire close to breaking. Repaired the wires with a little solder and tape and put everything back being mindful of the cable routing. I went for a ride this morning and at about 7 or 8 miles into the ride the computer reset and the light went out.
I know this is nothing new but with a lot of us long out of warranty this is an easy fix that retains the brake warning feature instead of shorting the wires together and doing without.

Bruce Hodges
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post #2 of 2 (permalink) Old Jun 26th, 2011, 2:58 pm
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Quote:
Originally Posted by bruce2000ltc
The brake warning light came on and with over 46000 miles I figured the brake pads had finally worn down enough to wear through the sensor wire. Checked the front and rear brake pads and they had plenty of wear left. I did a continuity check on the sensor wires and rear pad passed but the front pad failed. I removed the cable ties and felt for a break down the length of the front sensor cable and found a weak spot where the cable had been flexing. Opened it up and found one of the wires broken and the other wire close to breaking. Repaired the wires with a little solder and tape and put everything back being mindful of the cable routing. I went for a ride this morning and at about 7 or 8 miles into the ride the computer reset and the light went out.
I know this is nothing new but with a lot of us long out of warranty this is an easy fix that retains the brake warning feature instead of shorting the wires together and doing without.

Bruce Hodges
Bruce,

Thank you for sharing with the group. It is a good repair, and useful for everyone to know.

Just to be clear, the warning light is a nice-to-have failsafe, but you cannot depend on it. You MUST check your brake pads by visual inspection too. The problem is that the pad on the opposite side of the disk may wear out first, and it is not attached to the brake wear warning circuit.
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