Disassembly and Reassembly

Disassembly Procedure





1. Remove the caliper assembly.
2. Remove the caliper guide pin that connects the caliper piston housing to the retaining frame.





3. Remove the front pad brake set, including the pad springs, from the caliper.

Caution: Do not attempt to catch the piston when removing the piston with compressed air. The piston will pop out of its bore with enough force to damage a hand or finger.

Important: Insert a piece of hardwood into the caliper housing interior when removing the piston.

4. Using compressed air, blow out the piston from the housing.
5. Remove the outer seal.





6. Remove the inner seal from the caliper piston bore.





7. Remove the bleeder valve protector and the bleeder valve.
8. Pull out the pins and the rubber boots.

Assembly Procedure





1. Clean all parts in denatured alcohol or brake fluid. Dry the parts with unlubricated compressed air and blow out all passages in the housing and the bleeder valve.
2. Inspect the piston and the caliper for scoring, nicks, and corrosion. Replace components if these elements are found.
3. Inspect the caliper bleeder valve.

Important: Do not use a hone or any other procedure to remove material from the piston or the caliper bore.





4. Lubricate a new piston inner seal.
5. Install the piston inner seal into the caliper housing groove. Make sure the seal is not twisted.
6. Install the outer piston dust seal in the groove.
7. Lubricate the piston with brake fluid.
8. Push the piston into its bore and make sure the dust seal is seated in the piston groove.





9. Coat the pins with rubber grease and install the boots.





10. Install the caliper bleeder valve and the dust cap.
- Tighten the caliper bleeder valve to 6 Nm (53 inch lbs.).
11. Connect the brake pads and the pad springs.

Important: Make sure the pad springs are properly installed.





12. Connect the retaining frame to the caliper housing with the guide pin bolts.
- Tighten the retaining frame-to-caliper housing bolts to 27 Nm (20 ft. lbs.).
13. Install the caliper assembly.
14. Bleed the brake system.
15. Repeatedly apply the brakes until a firm pedal obtained.