Caliper Rubber Parts Replacement

Front Caliper Disassembly

• Remove: Front Caliper (see Front Caliper Removal in the Brakes chapter) Brake Pads (see Front Brake Pad Removal in the Brakes chapter)
• Remove: Front Caliper Assembly Bolts [A]
• Split the front caliper.

• Remove: Pad Spring O-ring [A]

• Using compressed air, remove the pistons. One way to remove the pistons is as follows.

Install a rubber gasket [A] and a wooden board [B] more than 10 mm (0.4 in.) thick on the caliper half.

For inside caliper half [C], fasten them together with a suitable bolt and nut [D] as shown. Leave one of the oil passage [E] open.

Lightly apply compressed air [F] to the oil passage until the pistons hit the rubber gasket.

Push down [G]

WARNING

The piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston.

Pull out the pistons by hand.

• Remove the dust seals [A] and fluid seals [B].
• Remove the bleed valve [C] and rubber cap [D].
• Repeat the previous step to remove the pistons from the other side of the caliper body.

NOTE

• If compressed air is not available, do as follows for both calipers coincidentally, with the brake hose connected to the caliper.
• Prepare a container for brake fluid, and perform the work above it.
• Remove the pad springs and pads (see Front Brake Pad Removal in the Brakes chapter).
• Pump the brake lever until the pistons come out of the cylinders, and then disassemble the caliper.

Front Caliper Assembly

• Clean the caliper parts except for the pads.

NOTICE

For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol.

• Install the bleed valve and rubber cap.

Torque - Bleed Valves: 7,8 N·m

• Replace the fluid seals [A] with new ones.

Apply silicone grease to the fluid seals, and install them into the cylinders by hand.

• Replace the dust seals [B] with new ones.

Apply silicone grease to the dust seals, and install them into the cylinders by hand.

• Replace the O-ring [A] and install it.
• Apply brake fluid to the outside of the pistons, and push them into each cylinder by hand.
• Be sure to install the O-ring.
• Tighten:

Torque - Front Caliper Assembly Bolts: 22 N·m

• Install the pad spring [A] as shown.
• Install the brake pads (see Front Brake Pad Installation in the Brakes chapter).
• Wipe up any spilled brake fluid on the caliper with wet cloth.

Rear Caliper Disassembly

• Remove: Rear Caliper (see Rear Caliper Removal in the Brakes chapter) Brake Pads (see Rear Brake Pad Removal in the Brakes chapter) Bolt [A] Caliper Bracket [B]

• Remove: Pad Spring [A] Dust Boot [B]

• Using compressed air, remove the piston.

Cover the caliper opening with a clean, heavy cloth [A].

Remove the piston by lightly applying compressed air [B] to where the brake line fits into the caliper.

WARNING

The piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston.

• Remove the dust seal and fluid seal.
• Remove the bleed valve and rubber cap.

NOTE

• If compressed air is not available, do as follows with the brake hose connected to the caliper.
• Prepare a container for brake fluid, and perform the work above it.
• Remove the pads (see Rear Brake Pad Removal in the Brakes chapter).
• Pump the brake pedal to remove the caliper piston.

Rear Caliper Assembly

• Clean the caliper parts except for the pads.

NOTICE

For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol.

• Install the bleed valve and rubber cap.

Torque - Bleed Valves: 7,8 N·m

• Replace the fluid seal [A] with a new one.

Apply silicone grease to the fluid seal, and install it into the cylinder by hand.

• Replace the dust seal [B] with a new one.

Apply silicone grease to the dust seal, and install it into the cylinder by hand.

• Install the pad spring [A] in the caliper as shown in the figure.
• Apply brake fluid to the outside of the piston [B], and push it into the cylinder by hand.
• Replace the and dust boot [C].

• Install the pad spring [A] on the caliper bracket as shown in the figure.
• Apply a silicone grease to the caliper bracket shaft [B].
• Replace the friction boot [C].
• Assemble the caliper and the caliper bracket.
• Apply silicone grease to the rear caliper pin bolt.
• Tighten:

Torque - Rear Caliper Pin Bolt: 27 N·m

• Install the pads (see Rear Brake Pad Installation in the Brakes chapter).
• Wipe up any spilled brake fluid on the caliper with wet cloth.