Overhaul

NOTE: Before disassembly, clean all around caliper with brake fluid.

REMOVAL
1. Remove anti-noise shim and blow compressed air into cylinder through bolt hole where flexible hose was fitted. With this air pressure, piston can be pushed out of cylinder.

WARNING: Do not apply too highly compressed air which will cause piston to jump out of cylinder. 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 piston seal using a thin, blade like a thickness gauge.

CAUTION: Be careful not to damage inside (bore side) of cylinder.

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

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 and piston seal to cylinder, apply fluid to them.
^ After reassembling brake lines, bleed air from them. Service and Repair

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 into cylinder, install boot onto piston as shown.

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.

5. Insert piston into cylinder by hand.
6. Install the anti-noise shim.

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

NOTE: Where temperature gets as low as -30�C in cold weather, use rubber grease whose viscosity varies very little even at - 40�C (-40� F).