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Installing Magura MT5 Brake Calipers on Dualtron Scooters

Upgrading to Magura MT5 brake calipers on your Dualtron scooter improves stopping power, modulation, and overall safety. The installation process is detailed but manageable with the right tools and careful attention to brake lines and fluid.

Tools Needed

  • Magura MT5 Brake Calipers

  • Banjo Kit

  • Allen wrench set

  • Star hex key set

  • Adjustable wrench

  • Brake fluid

  • Rag for cleanup

Step-by-Step Installation

Step 1: Remove Current Brake Calipers

  1. Unscrew the old calipers from their brackets using an Allen wrench (typically 5mm).

  2. Remove all brake lines from the scooter and brake levers.

  3. To remove handle grips, use an air blower at the end of the grip for easy removal.

Step 2: Determine Brake Line Entry Side

  • Some scooters require altering which side the brake line enters the caliper for easier installation.

  • Rule of thumb for Dualtrons:

    • 10" models: no modification needed.

    • Larger models: may need to switch sides.

  • Ensure larger circles on the calipers face away from the wheel.

Step 3: Switching Sides with the Banjo Kit (if needed)

  1. Unscrew the brake line from the calipers; be prepared for brake fluid spillage.

  2. Keep the yellow inserts in the calipers to protect the brake pads.

  3. Cut the brake line above the caliper entry point, stabilizing it with the yellow pieces.

  4. Install the banjo kit:

    • Place connecting bolt over line, followed by the gold piece.

    • Insert the olive into the brake line and secure it using a specialized vice grip.

    • Tighten the bolt with a screwdriver for stability and a wrench (torque 6–8 Nm).

  5. Reinstall into caliper and fill any remaining holes with screws.

Step 4: Installing Front Brake Calipers (Optional)

  • Shorten brake lines appropriately to prevent kinks and ensure smooth fluid flow.

  • Leave some extra length initially to allow adjustment.

Step 5: Install New Brake Calipers

  • Replace old brackets if necessary.

  • Ensure brake pads align properly around rotors.

  • Spin the wheel by hand to check for interference.

Step 6: Route Brake Lines to Handlebars

  • Secure lines without kinks, using zip ties or tape.

  • Ensure lines are long enough to reach brake levers comfortably.

Step 7: Install Brake Levers

  • Slide new brake levers onto handlebars and tighten securely.

Step 8: Refill Brake Fluid

  • Use a syringe to fill brake levers and lines completely.

  • Pump brake levers to remove air bubbles.

  • Test brakes to ensure proper engagement.

  • Clean up any spilled fluid with rags and alcohol.

Step 9: Reinstall Handle Grips

  • Firmly press grips onto handlebars; tap with a rubber mallet if necessary.

Notes

  • Take your time and keep the work area clean to avoid contamination of brake components.

  • Proper installation and bleeding of the hydraulic system are essential for optimal braking performance.