Brake Caliper: Service and Repair

1. Raise and support vehicle, then remove front wheel.
2. Disconnect brake hose.
3. Separate caliper body from caliper support.

CALIPER SERVICE

1. Remove dust boot.
2. Cover inner side of caliper with rag, then slowly inject compressed air through brake hose fitting to push out piston.
3. Remove piston seal, being careful not to damage cylinder.
4. Clean all metal parts and piston seal with brake fluid and clean dust boot with alcohol.
5. Check components for wear or damage, replacing as necessary. Use new piston seal, dust boot, and boot ring.
6. Apply rubber grease supplied with repair kit to piston seal, fit seal into cylinder groove, and install piston by hand, being careful not to twist seal.
7. Apply grease supplied with repair kit (1984-87, orange grease; 1988, pink grease) to dust boot attaching groove in caliper, then install dust boot.
8. Install brake pad.
9. On 1984-87 models, apply Plastilube 2 or equivalent brake grease to stopper plug and pad support plate sliding surface, then install caliper and spigot pin. On 1988 models, apply specified grease to the outer surface of guide pin and lock pin sleeves and the caliper body contacting surfaces of lock pin and guide pin boots, then install lock pin and guide pin.

CALIPER INSTALLATION

Reverse removal procedure to install, torquing brake hose fitting to 10-12 ft. lbs., then bleed brake system.