Front Brake Caliper

Removal

PROCEDURE

1. Raise the front of the vehicle and support it on stands.

2. Remove the wheel.

3. To minimize fluid loss, tightly close the reservoir cap with polyethylene film placed under it, or pinch off the hoses.

4. Clean the banjo fitting of the hose and remove the bolt.

5. Remove the two gaskets.

6. Remove the brake pads.

7. Remove the upper caliper guide pin.

8. Remove the caliper.

9. If necessary, remove the caliper bracket.

Disassembly

PROCEDURE

1. Carefully clean the caliper.

2. Pull out the guide pins by the bolt heads, which are screwed into the pins.

3. Remove the rubber guide pin boots.

4. Remove the retaining ring and the cylinder boot.

5. Remove the piston by applying air from a pump to the fluid inlet hole.

6. Using a wooden stick, remove the cylinder seal.

7. Wash all parts in clean brake fluid or alcohol.

8. All seals and boots must be replaced.

9. Inspect the caliper, especially the piston and the inner surface of the cylinder, and replace any worn parts. The caliper or caliper bracket is not available separately as a spare part.

10. Minor cylinder defects can be removed by polishing with fine emery cloth. A piston with the same defects must be replaced. Do not polish the piston.

11. Check the threads on the caliper guide pins. There must be no play in the pins in the caliper.

12. Blow out the passages in the caliper.

13. Before assembly, check that all parts are clean.

14. Dip the cylinder seal in brake fluid and install it in the cylinder groove.

15. Fit the edge of the boot into the cylinder groove, lubricate the piston and cylinder with brake fluid, install the piston into the cylinder, and fit the second edge of the boot onto the piston.

16. Fit new boots onto the caliper guide pins. Lubricate the pins with brake fluid before installing them into the caliper.

Installation

PROCEDURE

1. Install the caliper bracket and tighten the bolts.

2. Install the caliper, apply thread locking compound to the upper guide pin bolt threads, and tighten the bolt to the specified torque.

3. Install the brake pads.

4. Check that the caliper moves freely in the bracket.

5. Connect the hose, installing two new gaskets and tightening the banjo bolt.

6. Remove the polyethylene film from the reservoir cap (or remove the clamps from the hoses).

7. Bleed air from the hydraulic brake circuit of the wheel (if the integrity of other circuits was not affected).

8. Depress the brake pedal several times.

9. Install the wheel and lower the vehicle.