Front

DISASSEMBLY
1. Remove disc brake caliper.

CAUTION: Do not use a screwdriver or any similar tool to pry caliper piston out of bore. It will result in damage to piston. Cushion piston's impact against disc brake caliper when blowing it out of bore by placing shop towels or wood block between piston and caliper bridge.

WARNING: USE ONLY AS MUCH COMPRESSED AIR AS NECESSARY TO REMOVE THE PISTON. EXCESSIVE PRESSURE CAN FORCE THE PISTON OUT OF THE BORE WITH ENOUGH FORCE TO CAUSE PERSONAL INJURY. NEVER ATTEMPT TO CATCH THE PISTON BY HAND AS IT COMES OUT OF THE BORE.

Single Piston Caliper Component Location (Part 1 Of 2):

Single Piston Caliper Component Location (Part 2 Of 2):

2. Remove the caliper piston using air pressure. Apply air pressure to the fluid port in the disc brake caliper with rubber tipped air gun to remove caliper piston. If caliper piston is seized and cannot be forced from the disc brake caliper, tap lightly around the caliper piston while applying air pressure. If piston still will not come out caliper will need to be replaced.
3. Remove the dust boot from the caliper piston.
4. Remove brake piston seal from disc brake caliper.

INSPECTION

CAUTION: Do not use denatured alcohol for flushing the system or cleaning assemblies where alcohol could be trapped and cause eventual failure of rubber components in the system. Denatured alcohol is acceptable for cleaning parts, provided the parts are completely air-dried and coated with brake fluid before installation.

1. Clean all metal parts with isopropyl alcohol. Then clean out and dry grooves and passageways with compressed air. Make sure front disc brake bore and component parts are thoroughly clean.
2. Visually check disc brake caliper. If a caliper piston is seized in the bore, a new disc brake caliper is required.
3. Check the cylinder bore and caliper piston for damage or excessive wear. Replace the caliper piston if it is pitted, scored, corroded, or the plating is worn off.

ASSEMBLY
1. Clean any foreign material from caliper piston and disc brake caliper surfaces. Lubricate the caliper piston and disc brake caliper with brake fluid.
2. Install new seal into disc brake caliper groove.
3. Start caliper piston into disc brake caliper by hand to make sure components are correctly aligned.
4. Install dust boot into disc brake caliper. Apply very low air pressure to fluid port in disc brake caliper to inflate dust boot until it can be installed in caliper piston groove. Make sure dust boot is tight in boot groove on caliper piston and in front disc brake caliper.
5. When installing caliper piston back into bore, it may be necessary to use a wood block or another flat stock, like an old shoe lining assembly, between C-clamp and caliper piston. Do not apply C-clamp directly to caliper piston surface. This can result in damage to caliper piston. Make sure caliper piston is aligned properly.
6. Install front disc brake caliper as described.