Overhaul

Fig. 1 Disc Brake Assembly.:

Refer to Fig. 1, when servicing disc brake system.

1. Remove caliper.
2. Disassemble caliper as follows:
a. Remove piston boot, then the dust boot.
b. Remove bushing retainer, then the cylinder slide bushing.
c. Remove bleeder plug, then the plug cap.
3. Detach cylinder boot, using a suitable screwdriver.

Fig. 2 Removing Caliper Piston:

4. With a wooden piece or a cloth placed at the end of the disc cylinder, Fig. 2, drive out the piston by applying compressed air.
5. Detach the piston seal using a suitable screwdriver, do not score cylinder wall.
6. Apply lithium soap base glycol grease to piston and caliper, caliper boot and piston seal, inner surface of mounting pin and boot groove, sliding bushing and pin boot.
7. Install piston seal in caliper.
8. Install the piston into the caliper. Do not tilt piston during installation.
9. Assemble the cylinder boot in the caliper.
10. Assemble the cylinder boot set ring. Do not scratch the boot.