Front
BRAKE CALIPER ASSEMBLY: Disassembly and AssemblyBR-35 Exploded View:
DISASSEMBLY
NOTE:
Never remove the torque member and pad retainers when disassembling and assembling the cylinder body
1. Remove the sliding pin bolt, and remove the cylinder body from the torque member.
CAUTION:
Never drop pads, shims, shim covers and pad retainers from torque member.
2. Remove brake pads, shims and shim covers. Refer to BR-33, "BRAKE PAD: Exploded View". Front
3. Remove sliding pins and sliding pin boots from torque member.
4. Remove bushing from sliding pin.
5. Place a wooden block as shown in the figure, and blow air from union bolt mounting hole to remove pistons and piston boots.
CAUTION:
Never get fingers caught in the pistons.
6. Remove piston seal from cylinder body using suitable tool.
CAUTION:
Be careful not to damage a cylinder inner wall.
7. Remove bleeder valve and cap.
ASSEMBLY
1. Install bleeder valve and cap.
2. Apply rubber grease to piston seals (1), and install them to cylinder body.
CAUTION:
Never reuse piston seals.
3. Apply rubber grease to piston boots (1). Cover the piston (2) end with piston boot, and then install cylinder side lip on piston boot securely into a groove on cylinder body.
CAUTION:
Never reuse piston boots.
4. Apply brake fluid to pistons (1). Push piston into cylinder body by hand and push piston boot (2) piston-side lip into the piston groove.
CAUTION:
Press the pistons evenly and vary the pressing point to prevent cylinder inner wall from being rubbed.
5. Apply rubber grease to bushing, and install bushing to sliding pin.
6. Apply rubber grease to sliding pins and sliding boots, and install sliding pins and sliding pin boots to torque member.
7. Install the cylinder body to the torque member and tighten the sliding pin bolts to the specified torque.
BRAKE CALIPER ASSEMBLY: Inspection
INSPECTION AFTER DISASSEMBLY
Cylinder Body
Check the inner wall of the cylinder for rust, wear, cracks or damage. Replace the cylinder if any abnormal condition is detected.
CAUTION:
Always clean with new brake fluid. Never clean with mineral oil such as gasoline and light oil.
Torque Member
Check the torque member for rust, wear, cracks or damage. Replace the member if any abnormal condition is detected.
Pistons
Check the surface of the piston for rust, wear, cracks or damage. Replace the piston if any abnormal condition is detected.
CAUTION:
A piston sliding surface is plated. Never polish with sandpaper.
Sliding Pin and Sliding Pin Boot
Check the sliding pins and sliding boots for rust, wear, cracks or damage. Replace the parts if any abnormal condition is detected.
INSPECTION AFTER INSTALLATION
1. Check a drag of front disc brake. If any drag is found, follow the procedure described below.
2. Remove brake pads.
3. Press the pistons.
CAUTION:
^ Never damage the piston boot.
^ When replacing a pad with new one, check a brake fluid level in the reservoir tank because brake fluid returns to master cylinder reservoir tank when pressing piston in.
NOTE:
Use a disc brake piston tool to easily press piston.
4. Install brake pads.
5. Depress the brake pedal several times.
6. Check a drag of front disc brake again. If any drag is found, disassemble the cylinder body.
7. Burnish contact surface between disc rotors and brake pads according after refinishing or replacing disc rotor. Refer to BR-14, "BRAKE PAD: Inspection and Adjustment". Front