Assembly

CAUTION:
- Make sure all parts are clean before reassembly.
- Use only new replacement parts.
- Always use DOT 3 Brake Fluid. Using a non-DOT 3 brake fluid can cause corrosion and decrease the life of the system.
- Do not allow dirt or other foreign matter to contaminate the brake fluid.
- Avoid spilling brake fluid on painted, plastic or rubber surfaces as it can damage the finish. Wash spilled brake fluid off immediately with clean water.

1. Pack all cavities of the needle bearing with assembly lube.
2. Coat the new cam boot with assembly lube and install in the caliper.
3. Apply assembly lube to the pin contacting area of the cam, and install the cam and lever assembly into the caliper body.





4. Install the return spring.

CAUTION:
- If the cam and lever were separated, be sure to assemble them before installing the cam in the caliper body. Install the lever and spring washer, apply locking agent to the threads, and tighten the parking nut while holding the lever with a vise.
- Avoid damaging the cam boot since it must be installed before the cam.
- When installing the cam, do not allow the cam boot fins to turn outside in.

5. Install the pin in the cam.
6. Install a new O-ring on the sleeve piston.





7. Install the sleeve piston so the hole in the bottom of the piston is aligned with the pin in the cam, and the two pins on the piston are aligned with the holes in the caliper.
8. Install a new cup with its groove facing the bearing A side on the adjusting bolt.





9. Fit the bearing A, spacer, adjusting spring B and spring cover on the adjusting bolt, and install in the caliper cylinder.

NOTE: Install the bearing A with its open end facing the spacer.





10. Adjust the special tool as shown.
11. Install the special tool as shown.
12. Compress the spring until it bottoms out.
13. Check that the flared end of the spring cover is below the circlip groove.





14. Install the circlip, then remove the brake spring compressor.

NOTE: Check that the circlip is seated in the groove properly.





15. Install the adjusting nut, adjusting spring A, and washer, then secure with the circlip.

Rear Caliper Cut-Away View:

16. Coat the new piston seal and piston boot with silicone grease, and install them in the caliper.





17. Coat the outside of the piston with silicone grease, and install it on the adjusting bolt while rotating it clockwise.

CAUTION: Avoid damaging the piston and piston boot.