Front Brake Caliper Disassembly and Reassembly

Front Brake Caliper Disassembly and Reassembly
Reference: Front Brake Components

WARNING:
^ Do not place a finger between brake piston and front brake caliper when pushing out brake piston with compressed air.
^ Place shop towel (1) between brake piston and front brake caliper so as not to damage brake piston.
^ Push out brake piston slowly with appropriate air pressure to prevent piston from jumping out.





CAUTION:
Take care not to damage piston and cylinder of front brake caliper.

Disassembly

Caliper
1) Clean around front brake caliper.
2) Remove brake piston by blowing air into flexible hose joint bolt installation hole.
3) Remove cylinder boot (1) from caliper cylinder (3) of front brake caliper using flat-end screwdriver (2) or the like.





4) Remove piston seal and bleeder plug.

Slide pin
Remove slide pins (2) and pin boots (3) from front brake caliper carrier (1).





Reassembly

CAUTION:
^ Wash parts with specified brake fluid before assembling.
^ Do not use other brake fluid or volatile solvent.

Caliper
1) Perform the following procedures before installing brake piston to front brake caliper.
a) Check entire periphery of brake piston and inside face of cylinder for rust, corrosion and any other damage. If any fault is found, replace front brake caliper.
b) Apply rubber grease in piston seal set on new piston seal (1) and fit it into groove in caliper cylinder while taking care not to twist it.





c) Apply rubber grease to new cylinder boot (1). And then place lip (2) of cylinder boot onto caliper cylinder (3) of front brake caliper as shown.

NOTE:
Use rubber grease of which viscosity varies very little even at -40 degrees C (-40 degrees F).








d) Install cylinder boot using special tool.
Special Tool
(A): 09913-75510





2) Expand cylinder boot and install piston (1) into it. Then insert brake piston (1) into caliper cylinder (2) by hand and fit cylinder boot (4) in boot groove (3) on brake piston.

CAUTION:
Check that cylinder boot is fitted in boot groove securely all around piston.





3) Insert brake piston into caliper cylinder of front brake caliper.
4) Install bleeder plug to front brake caliper and tighten to specified torque.
Tightening torque
Bleeder plug: 8.0 Nm (0.82 kg-m, 6.0 lbf-ft)

Slide pin
1) Check the following points before installing slide pin to front brake caliper carrier.
a) Check slide pins for rust, corrosion and other damage and replace them if defective.
b) Apply grease to inner side of new pin boots (1).
c) Install pin boots (1) to front brake caliper carrier (2) as shown.

NOTE:
Use rubber grease of which viscosity varies very little even at -40 degrees C (-40 degrees F).





d) Apply grease to slide pins (1).

NOTE:
Use rubber grease of which viscosity varies very little even at -40 degrees C (-40 degrees F).





2) Install slide pins (1) to front brake caliper carrier (2) as shown.