Overhaul

REMOVAL
1) Before disassembly, clean all around caliper with brake fluid.
2) Remove piston boot retaining ring and boot from caliper; pry off with a flat-bladed tool. Be careful not to damage boot.





3) Blow compressed air into cylinder through bolt hole where flexible hose was fitted. With this air pressure, piston can be pushed out of cylinder.

WARNING: Do not apply too highly compressed air which will cause piston to jump out of cylinder. It should be taken out gradually with moderately compressed air. Do not place your fingers in front of piston when using compressed air.





4) Remove piston seal using a thin blade like a thickness gauge, etc.

NOTE: Be careful not to damage inside (bore side) of cylinder.

5) Remove bleeder plug and cap from caliper.

INSTALLATION
CAUTION:
- Wash each part cleanly before installation in the same fluid as the one used in master cylinder reservoir.
- Never use other fluid or thinner.
- Before installing piston and piston seal to cylinder, apply fluid to them.
- After reassembling brake lines' bleed air from them.





Slide Bush, Boot and Bleeder Plug
1) Check that slide bushes and boots for wear, corrosion, damage, movement or deterioration. If it is found faulty, correct or replace.
- Apply rubber grease to bush outer surface. And then make sure that each bush slides easily through each caliper bolt hole.

NOTE: Where temperature gets as low as -30°C (- 22°F) in cold weather, use rubber grease whose viscosity varies very little even at -40°C (- 40°F).

2) Tighten bleeder plug to specified torque and install cap.

Tightening Torque
(a): 11 N.m (1.1 kg-m, 8.0 ft. lbs.)

Piston Seal
3) Piston seal is used to seal piston and cylinder and to adjust clearance between pad and disc. Replace with a new one at every overhaul. Fit piston seal into groove in cylinder taking care not to twist it.





Piston and Boot
4) Before inserting piston into cylinder, install new boot onto piston as shown.





5) Fit boot as it is in figure into boot groove in cylinder with fingers.





6) Insert piston into cylinder by hand and fit boot in boot groove in piston.





7) To confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder a little but do not take it all out.

NOTE: Boot's face "B" should be at the same level from cylinder's face "A" all around.

8) Insert piston into cylinder by hand.
9) Install piston boot retaining ring.