I have been searching for the best way to replace the front brake pads on my 2006 KLX 250. Normally, you can remove the whole caliper and replace the pads once it's removed. However, on my 2006 KLX 250, the brake line is solid metal from about the hub to the caliper itself.

Is the best method to remove the front wheel to get to the pads?

I looked at the manual, but it almost seems like my brake line doesn't match the way the manual shows:




And here is how the manual shows it:

 

I'd say the easiest way to do them without having to remove the brake fluid bolt is exactly what you said. Take off the front wheel and change them out. I have a KLX650 that is the same way, where my '09 250 is not.

Some riders have changed that setup out to what the KLX650 guys called the CR wrap.



The front forks were pretty much the same forks, probably with a bit softer springs in the 250. This would solve your problem for the future.

 

Thank you for confirming the only way was taking the front wheel off. I wanted to make sure I wasn't missing anything. I was able to get my front brake pads replaced and it definitely helped my braking performance.

Is the main reason for doing that mod you outlined with the brake line to make it easier to work on the brakes as you would no longer have to take off the front wheel?

 

No, it was done to avoid crushing the line under the axle by a rock or something. I didn't do it on my KLX, but other riders did. I was mainly dual sporting on dirt/gravel. They were likely out west in rocky terrain. In the east here we encounter mud and ruts along with loose terrain, seldom any kind of rocks in our riding.