Fist Style Floating Caliper

Exploded View Fist Caliper Assembly:

1. Remove housing retaining spring, pull plugs out of guides, remove guide pins.
2. Remove housing, take outer brake pad off of holder. pull inner brake pad out of piston.
3. Support piston firmly on a piece of wood and press out of housing with compressed air. Press out piston only halfway at first and take sealing lip of dust cover out of piston groove.
4. Remove seal with a plastic needle.
5. Before assembly, apply a thin coat of brake cylinder paste or equivalent on cylinder bore, piston and seal.

Positioning Of Dust Cover:

6. Push dust cover on inside of piston so far that large diameter sealing lip extends over the piston.

Piston And Seal Installation:

7. Press sealing lip of dust cover into housing groove with piston in approximately correct position (20° set back surface). Make sure that seal fits properly around its entire periphery.

Piston Fully Seated, Sealing Lip Seated In Groove Of Piston.:

8. press piston into housing slowly, small diameter sealing lip should settle in groove of piston.

Aligning Piston To Correct Position:

9. Adjust 20° piston position precisely with the piston pliers. Set back surface of piston faces down to brake disc inlet side.

NOTE: A reference point is the edge on bottom of housing (see arrow). Arrow a=brake disc inlet side.

10. Replace damaged dampers and guides as needed.

Replacing Dampers And Slides:

11. Press out damper in direction of brake hose connection, make sure that bearing surface in housing is not damaged.
12. Coat damper with brake cylinder paste or equivalent.
13. Insert damper in housing from the brake hose connection side, then guide slide from piston side into damper so that it is positioned between the lips provided for this purpose (arrow=visible lip).
14. Bolt holder to housing. Tighten guide pins to specified torque. Insert brake pads and housing retaining springs.