Disassembly
Warning. It is not recommended to separate the caliper halves. All operations for replacing parts should be carried out on the assembled caliper.
Crush brake pads.
By pressing with a chisel, separate the protective caps from the guide pins.
Remove the piston protection cap from the caliper (see photo).
Slightly move the guide pins inside the caliper and remove the protective caps from the grooves of the guide pins.
Remove the protective caps of the guide pins.
Remove guide pins.
By forcing a jet of compressed air through the fluid inlet, push the piston out of the cylinder, placing a wooden plank 15-20 mm thick between the caliper and the piston so as not to damage the piston.
Clamp the caliper in a soft-grip vice and separate the caliper and wheel cylinder.
Remove the O-ring from the cylinder groove with a plastic wedge.
Remove the cuffs from the guide fingers.
Wash the parts in alcohol or brake fluid and check their condition.
Assembly
Install the O-ring into the cylinder groove.
Lubricate the piston with brake cylinder paste.
Insert the piston into the cylinder without sending it all the way.
Insert the piston cap into the groove of the cylinder and press it in using the KM 405 bushing or a mandrel of a suitable diameter.
Connect wheel cylinder to caliper. Install the cuffs on the guide pins, lubricating the sockets for them with grease from the repair kit.
Install the guide pins so that the groove for the protective cap is on the piston side.
Install new protective caps on the guide pins using tools KM 402 2 and KM 404 3.
Install brake pads.
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