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Hydraulic Brakes Replacement Guide for E-Bikes

Replacing hydraulic brakes on an e-bike can seem daunting, but with the right tools and guidance, it's a manageable task. This guide is designed to help you replace the hydraulic brakes on your e-bike, ensuring you can continue to enjoy safe and responsive braking. Remember, due to the added weight and speed capabilities of e-bikes, their brakes may wear out more quickly than those on traditional bikes, necessitating more frequent service.

Tools You'll Need:

  • Bike repair stand or lift
  • Flat-side cutters
  • Isopropyl alcohol
  • Paper towels
  • Flat-head screwdriver
  • Allen wrenches (2 mm, 2.5 mm, 3 mm, 4 mm, 5 mm)
  • Torque wrench
  • Zip ties
  • Brake pad separator (or a large, flat-head screwdriver)


  1. Safety First: Turn off the bike, remove the battery, and discharge remaining power by holding the Power button.
  2. Documentation: Take photos of the current brake setup for reference during reassembly.
  3. Identify the Caliper: Determine which caliper (front or rear) needs replacing. The rear caliper is connected to the right brake lever, and the front to the left.

Removal of Old Components:

  1. Caliper Removal: Use a 5 mm Allen wrench to remove the bolts securing the caliper to the frame or fork.
  2. Brake Hose Removal: Carefully remove the brake hose from its routing on the bike, cutting zip ties where necessary and using appropriate Allen wrenches to detach it from any clips or brackets.
  3. Handlebar Preparations: Depending on your e-bike's handlebar setup, you may need to remove grips or the throttle to access the brake lever. Use a flat-head screwdriver and Allen wrenches as needed to remove these components.
  4. Brake Lever Removal: Disconnect the brake lever from its cable and remove it from the handlebar using a 5 mm Allen wrench.

Installation of New Components:

  1. Install New Brake Lever: Slide the new brake lever onto the handlebar, adjusting its angle to match the opposite lever, and secure it using a 5 mm Allen wrench. Ensure the clamp bolt is torqued to specifications.
  2. Route and Secure Brake Hose: Properly route the new brake hose along the frame or fork, securing it with zip ties or clips as necessary. Be careful to avoid any sharp bends or kinks in the hose.
  3. Caliper Installation: Position the new caliper over the rotor, ensuring the brake pads are correctly aligned. Insert and partially tighten the caliper bolts to allow for adjustment.
  4. Align the Caliper: Squeeze the brake lever to align the caliper, ensuring even spacing between the brake pads and rotor. Tighten the caliper bolts and check for smooth, rub-free rotation of the wheel.
  5. Connect Brake Cable: Reconnect the brake cable to the lever, ensuring a secure and correct connection.
  6. Reassemble Handlebar Components: If removed, reinstall the throttle and grips, ensuring they are securely fastened and positioned for comfortable operation.
  7. Adjust Brake Lever Reach: If necessary, adjust the brake lever reach to ensure comfortable and effective braking without the lever contacting the handlebar grip.
  8. Final Checks: Replace any cut zip ties and secure all cables. Reinstall the battery and perform a thorough test of the bike, including the brakes, before riding.

Important Tips:

  • Never Disconnect the Brake Hose: The brake set (lever, hose, caliper) is a sealed system. Disconnecting any part can lead to fluid loss and air entering the system, compromising brake performance.
  • Work with Care: Hydraulic systems are sensitive to air bubbles and contaminants. Keep the system closed as much as possible and work in a clean environment.
  • Brake Fluid: If any brake fluid is lost or contaminated during the process, the brake system may need to be bled. This is a more advanced procedure and may be best left to a professional if you're unsure.

Safety Checks:

After completing the brake replacement, it's crucial to perform a series of safety checks before taking your e-bike out for a ride. Ensure that all bolts are tightened to the manufacturer's specifications, the brake levers are functioning smoothly, and there is no rubbing between the brake pads and rotor. Test the brakes at low speed in a safe area to confirm they are working correctly.

Replacing hydraulic brakes on an e-bike can significantly improve your riding experience and safety. However, if at any point you feel unsure about the process, consult a professional mechanic to avoid any potential issues.

If you have any inquiries or need further assistance, feel free to contact our support team at support@perraroelectricbike.com or call us at (949) 414-8003.

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