Note: When installing, use new brake hose coupler bolt o-rings.
Models with solid discs
Removing
1. Where applicable, remove the caps, then loosen the front wheel bolts and apply the handbrake. Jack up and support the front of the vehicle on axle stands. Remove the wheel.
2. Remove the brake pads as described in Chapter 4.
3. Working in the engine compartment, remove the brake fluid reservoir cap, cover the filler neck with a piece of polyethylene and secure it with a rubber band, or reinstall the cap. This will reduce fluid loss during the next procedure.
4. Remove the brake fluid hose connector bolt from the rear of the caliper and disconnect the hose. Remove the two O-rings from the coupling bolt. Be prepared for fluid to come out and plug open holes to prevent dirt from entering and further loss of fluid.
5. Use a screwdriver to pry off the dust caps on the two caliper bracket mounting bolts, then use a socket wrench to remove the mounting bolts and remove the caliper assembly.
Bulkhead
6. If necessary, disassemble the caliper as follows.
7. Clean off the dirt and dust from the caliper, being careful not to inhale particles that have risen into the air.
8. Clamp the caliper bracket in a vise. Then, separate the caliper body from the mounting bracket by pushing the face of the caliper body down while pulling the body off the dowel pins. Remove the spring guides from the bracket, noting their orientation.
9. Use a screwdriver to pry the mounting bracket off the piston dust seal, then carefully remove the dust seal itself in the same manner.
10. Place a thin plate in front of the caliper bore to prevent the piston from falling out. By forcing air into the brake hose port at the rear of the caliper housing, e.g. with a foot pump (air pressure should be low), drive the piston out of the hole.
11. Remove the wooden plate and carefully remove the piston.
12. Carefully remove the seal from the groove in the caliper bore using a plastic or wooden tool as a lever.
13. Examine the piston and walls of the channel of a support on existence of scratches and other damages. If these damages are found, replace the caliper assembly.
14. If the piston and bore are in good condition, discard the seals and purchase a repair kit containing all necessary parts.
15. Clean the piston and cylinder bore with brake fluid or methyl alcohol.
16. Begin assembly by placing the seal in the caliper bore.
17. Install the dust seal in the piston bore. Dip the piston in clean brake fluid and insert into the caliper bore. Make sure the piston slots are horizontal. If necessary, carefully rotate the piston.
18. Partially push the piston into the bore, insert the dust seal into the edge of the caliper bore and install the mounting bracket.
19. Push the piston a little more into the channel (but not to the point), to make sure it moves freely.
20. If necessary, replace the rubber part of the dowel pin housing» caliper. Remove the plastic sleeve from the pin, then gently squeeze the rubber part and push it out of the hole in the caliper body (see illustrations).
21. Install new rubber pins in reverse order.
22. Clamp the caliper bracket in a vice with soft jaws and set the spring guides to the position marked before removal.
23. Push the caliper body onto the mounting pins of the bracket.
Installation
24. Install the caliper bracket on the hub fastener and tighten the fastening bolts with a tightening torque regulated specifications. Install dust caps on bolts
25. Connect the brake fluid hose using new coupler bolt o-rings.
26. Install the brake discs as described in Chapter 4.
27. Remove the polyethylene from the filler neck of the brake fluid reservoir and bleed the corresponding hydraulic line as described in Chapter 3.
28. Install the wheel and lower the vehicle to the ground. Do not fully tighten the wheel bolts until the vehicle is lowered onto the wheels.
Models with ventilated discs
Removing
29. Proceed as described in points 1-4.
30. Remove the caliper body.
31. If required, remove the caliper bracket from the swingarm by unscrewing the two mounting bolts (see illustration).
Bulkhead
32. If it is not necessary to disassemble the caliper, go to step 42.
33. Clean off dirt and dust from the caliper, being careful not to inhale particles that have risen into the air.
34. Carefully remove, using a screwdriver as a lever, the dust seal from the end of the piston and caliper body.
35. Proceed as described in paragraphs 10-15.
36. Start assembly by installing the seal in the caliper bore.
37. Install a dust seal in the piston bore Dip the piston in clean brake fluid and insert it into the caliper bore Make sure the piston slots are horizontal. If necessary, carefully rotate the piston to the correct position.
38. Partially push the piston into the channel, insert the dust seal into the edge of the caliper channel.
39. Push the piston a little more into the channel (but not to the point), to make sure it moves freely.
40. If necessary, replace the rubber portion of the caliper housing dowel pin. Remove the plastic bushing from the pin, then gently squeeze the rubber part and push it out of the hole in the caliper body.
41. Install new rubber pins in reverse order.
Installation
42. Where applicable, install the caliper bracket on the pivot arm and tighten the mounting bolts to the specified torque specifications.
43. Proceed as described in paragraphs 25-28.
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