Front Disc Brake Caliper Disassembly and Assembly
Front Disc Brake Caliper Disassembly and AssemblyDisassembly
NOTE:
Before disassembly, clean all around caliper with brake fluid.
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.
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.
Assembly
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 cylinder boot to cylinder, apply fluid to them.
^ After reassembling brake lines, bleed air from them.
^ Before installing piston to cylinder, apply rubber grease to inside (bore side) of cylinder.
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 (1) into cylinder, apply brake fluid to new cylinder boot (a) and piston (1). Install cylinder boot onto piston as shown in figure.
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.
NOTE:
Boot's face (1) should be at the same level from cylinder's face (2) all around.
5. Install piston into cylinder by hand.
Caliper
Before installing caliper (cylinder body) to carrier, check to ensure that guide pin (pin bolt) inserted in each caliper carrier hole can be moved smoothly in thrust direction.