Front Brakes
Front Brake Caliper Disassembly and Reassembly
Front Brake Components
CAUTION:
If you place your fingers in front of the piston when you push it out with compressed air, you may hurt your fingers.
Do not place your fingers in front of the piston when removing it using compressed air.
NOTE:
- Using compressed air that is under high pressure can force the disc brake piston quickly out of the cylinder and damage the piston.
Use a moderate air pressure to push the piston out of the cylinder slowly. In addition, place a cloth (1) in front of the piston to prevent it from being damaged.
- If the inside surface of the cylinder (bore wall) and outside surface of piston are damaged, brake fluid leaks may result.
Be extremely careful not to damage the inside surface of the cylinder and outside surface of piston when removing the piston seal.
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-bladed 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
WARNING:
Failure to take proper precautions when assembling the brake caliper can result in brake system failure, which could lead an accident.
- Clean each part before installation using the same brake fluid as that in the master cylinder reservoir. Never use any other brake fluid or volatile solvent.
- Before installing the piston seal and cylinder boot to the cylinder, apply rubber grease included in the piston seal set or brake fluid to them.
- Fit a new piston seal, securely into the groove of the cylinder making sure that it is not twisted.
NOTE:
If you do not bleed air from the brake system after replacement of a brake pipe or hose, brake system performance may be affected.
Be sure to bleed the brake system referring to Service and Repair Air Bleeding of Brake System
after replacement of a brake pipe or hose.
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 whose viscosity varies very little even at -40°C (-40°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.
NOTE:
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 kgf-m, 6.0 lbf-ft)
Slide pin
5) 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 whose viscosity varies very little even at -40°C (-40°F).
d) Apply grease to slide pins (1).
NOTE:
Use rubber grease whose viscosity varies very little even at -40°C (-40°F).
6) Install slide pins (1) to front brake caliper carrier (2) as shown.
