Front Brakes

Front Disc Brake Caliper Disassembly and Reassembly

Front Disc Brake Caliper Removal and Installation

Disassembly

NOTE:

Before disassembly, clean all around caliper with brake fluid.

1) Remove disc brake piston with air blown into flexible hose joint bolt installation hole.

CAUTION:
If you place your fingers in front of the piston when you push it out with compressed air, you may hurt your fingers.

Do not place your fingers in front of the piston when removing it using compressed air.

NOTE:
Using compressed air that is under high pressure can force the disc brake piston quickly out of the cylinder and damage the piston.

Use a moderate air pressure to push the piston out of the cylinder slowly. In addition, place a cloth (1) in front of the piston to prevent it from being damaged.





2) Remove cylinder boot.
3) Remove piston seal using a thin blade like a thickness gauge, etc.

NOTE:
If the inside surface of the cylinder (bore wall) is damaged, brake fluid leaks may result.

Be extremely careful not to damage the inside surface of the cylinder when removing the piston seal.





4) Remove bleeder plug and cap from caliper.

Reassembly

Front Disc Brake Components

Front Disc Brake Caliper Removal and Installation

Front Disc Brake Caliper Inspection

Reassemble front brake in reverse order of disassembly, noting the following points.

NOTE:

- Failure to take proper precautions when assembling the brake caliper can result in brake system failure.

- Clean each part before installation using the same brake fluid as that in the master cylinder reservoir. Never use any other brake fluid or volatile solvent.
- Before installing the piston seal and cylinder boot to the cylinder, apply rubber grease included in the piston seal set or brake fluid to them.
- Fit a new piston seal securely into the groove of the cylinder making sure that it is not twisted.

- If you do not bleed air from the brake system after replacement of a brake pipe or hose, brake system performance may be affected.
Be sure to bleed the brake system referring to Service and Repair Air Bleeding of Brake System
after replacement of a brake pipe or hose.

Piston seal

Piston seal is used to seal piston and cylinder and to adjust clearance between pad and disc. Replace with a new one at every overhaul. Fit piston seal into groove in cylinder taking care not to twist it.

Piston and boot

1) Before inserting piston (1) into cylinder, apply brake fluid to new cylinder boot (a) and piston (1). Install cylinder boot onto piston as shown in figure.











2) Fit boot as it is in above figure into boot groove in cylinder with fingers.





3) Insert piston into cylinder by hand and fit boot in boot groove in piston.





4) To confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder a little but do not take it all out.

NOTE:
Boot's face (1) should be at the same level from cylinder's face (2) all around.





5) Install piston into cylinder by hand.

Caliper

Before installing caliper (cylinder body) to carrier, check to ensure that guide pin (pin bolt) inserted in each caliper carrier hole can be moved smoothly in thrust direction.