Disassembly and Assembly

DISASSEMBLY

CAUTION:
Be careful not to allow foreign matter to enter the brake hose connector.

1) Remove mud and foreign matter from the caliper body assembly.
2) Remove the piston boot from caliper body cylinder.





3) Remove the piston - disc brake.
(1) Place a wooden block in the caliper body assembly as shown in the figure to prevent the piston - disc brake from jumping out and being damaged.
(2) Using an air gun, gradually apply compressed air via the brake hose installation hole to push out the piston - disc brake.





4) Remove the piston seal from caliper body cylinder.

CAUTION:
Do not damage the cylinder and piston seal groove.





5) Remove the guide pin - front brake, lock pin - rear brake, lock pin - sleeve, and pin boot from the support - rear disc brake.





ASSEMBLY

1) Before installation, check each part.
2) Clean the inside of the caliper body cylinder using brake fluid.
3) Apply a coat of brake fluid to piston seal and install the piston seal to the caliper body cylinder groove.
4) Apply a coat of brake fluid to the inner surface of caliper body cylinder and the entire outer surface of the piston - disc brake.
5) Apply grease contained in the piston seal kit to the piston boot, and install it to the groove at the end of the cylinder.
6) Insert the piston - disc brake into the caliper body cylinder.

CAUTION:
Do not force the piston - disc brake into the caliper body cylinder.

7) Position the piston boot in the grooves on the piston - disc brake and the caliper body cylinder.





8) Apply grease contained in the piston seal kit to the lock pin - rear brake, the outer surface of guide pin - front brake, the inner surface of support cylinder, and the grooves of pin boot.
9) Install the pin boot to the lock pin - rear brake and guide pin - front brake, and insert them into the support cylinder.

CAUTION:
Insert the lock pin - rear brake and guide pin - front brake into specified position, and make sure that they slide and seat properly.