Front Brakes

Front Disc Brake Caliper Disassembly and Reassembly

Front Disc Brake Components

Front Disc Brake Caliper Removal and Installation

Disassembly

WARNING:

If dust or other impurities get into the brake system, they can cause brake failure, which could lead to an accident.

Clean the surfaces on and around the caliper with brake fluid before disassembling it.

1) Remove disc brake piston with air blown into flexible hose joint bolt installation hole.

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.






2) Remove cylinder boot.
3) Remove piston seal using a thin blade like a thickness gauge, etc.

NOTE:
If the inside surface of the cylinder (bore wall) is damaged, brake fluid leaks may result.

Be extremely careful not to damage the inside surface of the cylinder when removing the piston seal.





4) Remove bleeder plug and cap from caliper.

Reassembly

Front Disc Brake Caliper Check

Assemble parts in reverse order of disassembly, observing the following instructions.

WARNING:

Failure to take proper precautions when assembling the brake caliper can result in brake system failure, which could lead to 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.

Before installing caliper to carrier, install slide pins with rubber grease included in slide pin / boot set applied into caliper carrier hole and check for its smooth movement in thrust direction.





Check all around piston for rust, corrosion and any other damage. If it is found faulty, replace piston or brake caliper.





- Install piston seal, boot and piston to caliper referring to the following instructions.

1) Replace with a new piston seal (1) at every overhaul. After applying rubber grease included in piston seal set or brake fluid, fit piston seal (1) into groove in cylinder taking care not to twist it.





2) Before inserting piston (1) into cylinder, apply rubber grease included in piston seal set or brake fluid to new boot (a) and install it onto piston as shown.











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






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

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





5) 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 (1) should be at the same level from cylinder's face (2) all around.

6) Insert piston into cylinder by hand.