HP-2 Dual Piston Calipers - Aluminum
Note:
^ Always install complete repair kit
^ After replacing brake pads and before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position.
^ When siphoning brake fluid, always use a bleeder bottle that is used exclusively for brake fluid. Brake fluid is poisonous. NEVER siphon brake fluid with your mouth!
^ Brake line tightening torque: 15 Nm.
1. Brake disk
^ Pads on both sides of axle must always be replaced together.
^ Check for sufficient wear limit.
^ Remove brake caliper before removing
2. Brake caliper
^ If repair work is necessary, do not hang by brake hose. Secure on structure using wire
^ No repair work is permitted at the brake caliper except for "replacing brake pads" and "servicing front brake caliper".
3. Line retainer for wear indicator
^ Insert line for brake pad wear indicator in line retainer
4. Ribbed washer
5. Ribbed bolt w/washer assembly, 190 Nm
^ Clean ribs if reusing
6. Tensioning spring
^ Slide to side
^ Not removable
7. Retaining spring
8. Harness connector
^ Only on vehicles with wear indicator
9. Brake hose
^ Do not unscrew brake pads when removing
10. Hex bolt, 25 Nm
11. Bracket
^ Bolt to brake caliper housing
^ Insert harness connector for brake pad wear indicator
12. Brake line, 15 Nm
13. Brake pads
^ Pads on both sides of axle must always be replaced together.
^ Different on left and right side
^ Removing and installing; Refer to brake pads
^ With wear indicator
- Warning lamp lights when relevant wear limit (3 mm) has been reached
- The outer brake pads have an adhesive foil on the pad backing plate. Remove the protective foil before inserting.
Brake pads, removing and installing
Removing
Note: When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven!
- Raise vehicle.
- Remove wheels.
- Secure brake disk using a wheel bolt.
- Disconnect connector for brake pad wear indicator
- Disengage connector from bracket using screwdriver and simultaneously turn connector 90 �
- Lift connector up and out and disengage wire
- Press upper and lower spring tensioner out of locking mechanism using pliers (arrows).
- Slide spring to side.
Note: Before pushing back the piston, siphon some of the brake fluid out of file fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.
WARNING: Brake fluid is poisonous. NEVER siphon brake fluid with your mouth!
- Press piston back into brake caliper housing.
- To do this, insert floating frame using a screwdriver as shown and press powerfully outward.
- First use screwdriver to press outer brake pads off brake caliper.
- Press floating frame powerfully in direction of arrow until stop.
- Carefully press brake pads out of piston and remove brake caliper housing.
Note:
Clean brake caliper housing thoroughly before installing new brake pads.
Be especially careful to remove any residual adhesive foil, left by outer brake pads.
Installing
- Insert lower and upper brake pads in piston.
Note:
^ Be sure protrusions on backing plates are securely fitted in brake piston.
^ Do not damage protective caps when installing brake pads.
- Press floating frame outward until stop.
- Remove protective foil on backing plates of outer brake pads.
- Be sure protrusions on backing plate are securely fitted in floating frame.
Note: After replacing brake pads and before moving vehicle, always depress brake pedal several times firmly to properly seat brake pads in their normal operating position.
- Remove wheel bolt from wheel hub.
Note:
When installing wheels, be sure rim flange does not rest on brake caliper.
This could push brake pads out of position.
- Tighten wheels to 120 Nm when installing.
- Check brake fluid level and top off, if necessary.