Disassembly and Assembly
Disassembly1. Remove guide bolt.
2. Remove lock bolt.
3. Remove dust boot; guide bolt and lock bolt.
Removing Dust Boot Ring:
4. Remove dust boot ring, using a small screwdriver.
Forcing Out Piston With Compressed Air:
5. Insert a block of wood into the caliper and force out the piston by blowing compressed air into the caliper at the flexible hose attachment. This procedure must be done prior to removal of the dust boot. Remove piston.
Warning: Do not place your fingers in front of the piston in an attempt to catch or protect it when applying compressed air. This could result in personal injury.
Caution: Use just enough air to ease the piston out of the bore. If the piston is blown out, it may be damaged.
6. Remove dust boot: piston.
7. Remove piston seal.
8. Remove bleeder with cap.
9. Remove caliper body.
Inspection and Repair
Make necessary parts replacement, if wear, damage, corrosion or any other abnormal conditions are found through inspection.
Check the following parts:
^ Rotor
^ Cylinder body
^ Cylinder bore
^ Piston
^ Guide bolt, lock bolt
^ Support bracket
Note: The piston dust seal and dust boot are to be replaced each time the caliper is overhauled. Discard these used rubber parts and replace with new ones.
Reassembly
1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the specified torque.
Torque: 8 Nm (69 ft. lbs.)
Applying Grease To Piston Seal & Cylinder Wall:
3. Install piston seal and apply special rubber grease to the piston seal and cylinder wall, then insert the piston seal into the cylinder. The special rubber grease is included in the repair kit.
Inserting Piston Into Cylinder:
4. When inserting the piston into the cylinder, use finger pressure only and do not use a mallet or other impact tool, since damage to the cylinder wall or piston seal can result. Install piston.
Removing Dust Boot Ring:
5. Apply special grease (approximately 1 g) to the piston and attach the dust boot to the piston and caliper. Insert the dust boot ring into the dust boot.
6. Install guide bolt and lock bolt dust boot.
Applying Grease Onto Lock Bolt And Guide Bolt Setting Hole:
7. Install the dust boot on the support bracket after applying special grease (approximately 1 g) onto the dust boot inner surface. Also apply special grease onto the lock bolt and guide bolt setting hole of the support bracket.
8. Install lock bolt and guide bolt and tighten the bolt to the specified torque.
Torque: 44 Nm (32 ft. lbs.)