Overhaul
Front Brake Caliper Overhaul
Removal Procedure
Warning: Refer to Brake Dust Warning (Brake Dust Warning).
Warning: Refer to Brake Fluid Irritant Warning (Brake Fluid Irritant Warning).
1. Remove the brake caliper. Refer to Front Brake Caliper Replacement (Front Brake Caliper Replacement).
Warning
Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury.
Caution: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged.
2. Press the piston out of the brake caliper.
* Clamp the brake caliper in the vice.
* Insert the hardwood block in the brake caliper shaft.
* Carefully press out the piston with compressed air.
3. Lever the protective cap out of the brake caliper housing carefully with a plastic wedge.
4. Lever the seal ring (1) carefully out of the groove in the brake caliper housing with a plastic wedge.
5. Press the sliding sleeve (2) out of the housing.
Note: Only with brake fluid or alcohol, never use other fluids.
6. Clean piston and bore.
7. Replace the seal ring and the protective cap.
Note: If the piston is defective or seized with rust, replace the entire brake caliper.
8. Inspect the piston and bores for wear.
Installation Procedure
Note:
* Lip (3) of the protective cap must sit in the groove (2) on the brake caliper.
* Until the inner lip of the protective cap has engaged in the groove on the piston. Ensure that the piston is not askew.
1. Install the piston in the brake caliper.
* Coat the bore, piston and seal ring with brake cylinder paste.
* Press in the new sliding sleeve.
* Insert a new seal ring (1).
* Insert the protective cap in the brake caliper.
* Push the piston in carefully.
2. Install the brake caliper. Refer to Front Brake Caliper Replacement (Front Brake Caliper Replacement).