Disassembly and Assembly

DISASSEMBLY AND ASSEMBLY





LUBRICATION POINTS

DISASSEMBLY SERVICE POINTS

CAUTION: When disassembling the front disc brakes, disassemble both sides (left and right wheels) as a set.

<> PISTON BOOT/PISTON REMOVAL

CAUTION:
^ When removing the pistons, be sure to use the handle of a plastic hammer and adjust the height of the two pistons while pumping in air slowly so that the pistons protrude evenly.
^ Do not remove one piston completely before trying to remove the other piston, because it will become impossible to remove the second piston.
^ Blow air little by little to remove the piston. The piston will rush out if a force of air is applied suddenly.

Blow compressed air slowly from the connecting portion of the brake hose to pull out the piston and the piston boots.

<> PISTON SEAL REMOVAL

CAUTION: Do not use a flat-tipped screwdriver or similar tool to remove piston seal. These may damage the inner side of the cylinder.

1. Remove the piston seal with your finger tip.
2. Clean the piston surface and inner cylinder with alcohol brake fluid DOT 3 or DOT 4.

INSPECTION
^ Check the cylinder for wear, damage or rust.
^ Check the piston surface for wear, damage or rust.
^ Check the caliper body or sleeve for wear.
^ Check the pad for damage or adhesion of grease.
^ Check the backing metal for damage.

Pad Wear Check

WARNING:
^ Always replace both brake pads on each wheel as a set (both front wheels or both rear wheels). Failure to do so will result in uneven braking, which may cause unreliable brake operation.
^ If there is significant difference in the thickness of the pads on the left and right sides, check the sliding condition of the piston, lock pin and guide pin.

Measure thickness at the thinnest and most worn area of the pad. Replace the pad assembly if pad thickness is less than the limit value.
Standard value: 10 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)