Caliper Overhaul

Disassemble

Removal of Inner Protective Caps
A. CHISEL.

B. VISE.

4. INNER CALIPER HOUSING.

22. GUIDE BUSHING INNER PROTECTIVE CAPS

Removal of Piston Protective Boot
A. CHISEL.

4. INNER CALIPER HOUSING.

7. PISTON PROTECTIVE BOOT

Removal of Guide Bushing

20. GUIDE BUSHING.

21. BUSHING SEAL

Removal of Piston
A. WOODEN BLOCK.

B. VISE.

C. AIR HOSE NOZZLE WITH COMPRESSED AIR.

4. INNER CALIPER HOUSING.

9. PISTON.

24. OUTER CALIPER HOUSING

Disassembly of caliper. A. Torx wrench.

4. INNER CALIPER HOUSING.

24. OUTER CALIPER HOUSING

Removal of Piston Seal
A. WOODEN (PLASTIC) TOOL.

B. VISE.

4. CALIPER HOUSING, INNER PART.

8. PISTON SEAL

PROCEDURE.

1. Remove the brake caliper.

2. Remove the brake pads from the caliper.

3. Using a chisel, remove the inner protective caps of the guide bushings from

the seats on the caliper housing.

4. Remove piston protective boot 7 from the caliper bore.

5. Slightly push guide bushings 20 into the caliper and remove the caps from the bushing grooves.

6. Remove protective boot 7 from the piston and the caliper bore.

7. Push guide bushings 20 outward from the caliper and remove seals 21 using a wooden or plastic tool.

8. Press piston 9 out of the caliper cylinder using compressed air.

Warning.

Do not hold the piston with your fingers while pressing it out of the cylinder with

compressed air. This may result in serious injury.

Insert a hardwood block 15–20 mm thick into the caliper window

when removing the piston.

9. Unscrew the bolts and separate caliper parts 4 and 24. Clamp the caliper in a vise.

10. Remove piston seal 8 from the caliper cylinder groove using a suitable wooden or plastic tool.

Do not use metal tools, as they may damage the cylinder bore or the groove.

11. Unscrew the bleeder valve.

Clean.

PROCEDURE.

1. Clean all parts with alcohol or fresh brake fluid.

2. Dry parts with a jet of oil-free compressed air.

3. Blow out all holes in the caliper housing and the bleeder valve.

Inspection.

PROCEDURE.

1. Check the piston and cylinder bore for:

– scratches.

– nicks.

– signs of corrosion.

2. Replace defective parts.

3. If any part shows signs of corrosion, replace the caliper assembly.

Warning.

Do not machine the cylinder bore or piston in any way that removes metal.

Assembly

Installation of Piston
A. WOODEN BLOCK.

4. INNER CALIPER HOUSING.

9. PISTON

PROCEDURE.

1. Install the lubricated piston seal 8 into the cylinder groove. Make sure the seal is not twisted.

2. Install the lubricated piston 9 into the caliper cylinder. Carefully insert piston 9 into the cylinder. When installing the piston, make sure

the piston does not bind and the seal sits properly in the cylinder groove. Do not

fully push the piston into the cylinder. Leave the edge of the piston outside for

installing the protective boot into the piston groove.

3. Install protective boot 7 into the piston groove and onto the caliper housing.

4..

4. Install piston protective boot 7 using installation tool KM-

405..

5. Connect caliper parts 4 and 24 and thread in the bolts. Tighten the bolts to torque 95 N·m.

6. Install seals 21 onto the guide bushings

20. Coat bushings 20 with a thin layer of the grease supplied in the spare parts kit..

7. Install seals 21 into the grooves of the guide bushings

20. Make sure that

the seals in the grooves are not twisted..

8. Insert the guide bushings into the holes in the caliper. The grooves for the inner

protective caps 22 must face the piston

9. Check that the bushings move smoothly

in the caliper. Extend the bushings outward to install the inner protective caps..

9. Install the inner protective caps into the grooves of bushings 20 and press the caps onto the seats of the caliper body

4..

10. Secure protective caps 22 using tool KM-404A..

Warning.

Use only new protective caps..

11. Push guide bushings 20 into the caliper

4..

12. Install the bleeder valve..

13. Install the brake pad with the pad wear sensor into the caliper (on the piston

side)..

Warning.

Make sure the pins and retaining springs are installed correctly..

14. Install the caliper in place.