Front Brake Caliper, Servicing

Front brake caliper, servicing

CAUTION: Always install all the parts that are included in the repair kit.

NOTE: Lightly coat the brake caliper bores, pistons and piston seals with brake cylinder paste B 000 100.






1. Self-Locking Bolt 35 Nm (26 ft lb)
Always replace
Loosening and tightening: counter-hold at guide pin

2. Bleeder Valve
Before installing, grease threads lightly with brake cylinder paste

3. Dust Cap
For bleeder valve

4. Brake Caliper Housing

5. Piston Seal
Remove using screwdriver - Fig. 2.

6. Piston
Diameter: 40/45 mm
Installing - Fig. 3, Fig. 4 and Fig. 5
First coat piston lightly with brake cylinder paste
Removing from brake caliper housing with compressed air - Fig. 1

WARNING: Risk of accident! Apply pressure gradually. Guard against sudden release of the piston.
Place wooden board into the recess of the caliper housing to catch the pistons so that they are not damaged - Fig. 1.


7. Protective Cap
Outer sealing lip fits on piston - Fig. 3.
Inner sealing lip fits in groove in caliper housing - Fig. 4.

8. Brake Pad Carrier With Guide Pins And Protective Caps
Replacement part supplied assembled with sufficient grease on guide pins
Install repair kit if protective caps are damaged
Use grease included with kit to grease guide pins

9. Guide Pin
Grease before installing protective caps

10. Protective Cap
Attach to brake pad carrier and guide pin






Fig. 1 Removing pistons from brake caliper housing

WARNING: Risk of accident! Apply pressure gradually. Guard against sudden release of the piston.
Place wooden board into the recess of the caliper housing to catch each piston so that it is not damaged.

Press pistons out of brake caliper housing individually using compressed air.
Hold one piston in housing with press tool.
Use compressed air to force other piston out.
Use compressed air to force remaining piston out.






Fig. 2 Removing Piston Seals
Carefully remove piston seals using screwdriver.






Fig. 3 Install Protective Cap With Outer Sealing Lip On Piston






Fig. 4 Installing Inner Sealing Lip Of Protective Cap
Press gently into groove in brake caliper housing using screwdriver.

NOTE: During this process, hold the piston in position in front of the brake caliper housing.






Fig. 5 Pressing Piston Into Brake Caliper Housing
Use piston resetting device to press pistons into brake caliper housing.

NOTE: While pressing in, the outer sealing lip of the protective cap seats in the groove of the piston.