Disassembly and Reassembly
DisassemblyCAUTION: Clean around caliper with brake fluid before disassembly.
1. Remove piston with air blown into flexible hose bolt installation hole.
WARNING: Do not apply too highly compressed air which will cause piston to jump out of cylinder. Place a cloth (1) to prevent piston from damage. It should be taken out gradually with moderately compressed air. Do not place your fingers in front of piston when using compressed air.
2. Remove retaining ring (1) and cylinder boot (2).
CAUTION: Be careful not to damage inside (bore side) of cylinder.
3. Remove piston seal using a thin blade like a thickness gauge, etc.
CAUTION: Be careful not to damage inside (bore side) of cylinder.
4. Remove bleeder plug and cap from caliper.
Reassembly
Assemble parts in reverse order of disassembly, observing the following instructions.
CAUTION:
^ Wash each part cleanly before installation in the same fluid as the one used in master cylinder reservoir.
^ Never use other fluid or thinner.
^ Before installing piston seal or cylinder boot to cylinder, apply grease to them.
^ Install a new piston seal into groove in cylinder securely making sure that it is not twisted.
^ Before installing caliper to carrier, install slide pin with grease applied into caliper carrier hole and check for its smooth movement in thrust direction.
^ After reassembling brake lines, bleed air from them.
^ Install piston seal, boot, piston and retaining ring to caliper.
1. Replace with a new piston seal (1) at every overhaul. After applying grease, fit piston seal (1) into groove in cylinder taking care not to twist it.
2. Before inserting piston (2) into cylinder, apply grease to new boot (1) and install it onto piston as shown.
"A": 1-grooved side directed cylinder side
"B": 2-grooved side directed pad side
3. Fit boot as it is in figure into boot groove in cylinder with fingers.
4. Insert piston into cylinder by hand and fit boot in boot groove in piston.
NOTE: Check that boot is fitted in boot groove securely all around piston and cylinder.
5. Install cylinder boot retaining ring (2) to cylinder boot (1) as shown in figure.
CAUTION: Use care not to cause damage to cylinder boot.
Front Disc Brake Caliper Inspection
Pin Boot and Cylinder Boot
Check boots for breakage, crack and damage. If defective, replace.
Piston Seal
Excessive or uneven wear of pad lining may indicate unsmooth return of piston.
In such case, replace rubber seal.