Front Disc Brake

FRONT DISC BRAKE


BRAKE CALIPER ASSEMBLY : Disassembly and Assembly


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 Brake Pad.
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.