Front Disc Brake Caliper Disassembly and Assembly
Front Disc Brake Caliper Disassembly and AssemblyDisassembly
CAUTION: Clean around caliper with brake fluid before disassembly.
1. Remove disc brake piston with air blown into flexible hose joint 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 cylinder boot.
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.
Assembly
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 and cylinder boot to cylinder, apply rubber grease included in piston seal set or brake fluid to them.
^ Install a new piston seal into groove in cylinder securely making sure that it is not twisted.
^ After reassembling brake lines, bleed air from them.
Before installing caliper to carrier, install slide pins with rubber grease included in slide pin / boot set applied into caliper carrier hole and check for its smooth movement in thrust direction.
^ Install piston seal, boot and piston to caliper referring to the following instructions.
1. Replace with a new piston seal (1) at every overhaul. After applying rubber grease included in piston seal set or brake fluid, fit piston seal (1) into groove in cylinder taking care not to twist it.
2. Before inserting piston (1) into cylinder, apply rubber grease included in piston seal set or brake fluid to new boot (a) and install it onto piston as shown.
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. 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.
6. Insert piston into cylinder by hand.
