Overhaul

WARNING: To prevent bodily injury, make sure to keep fingers or other body parts away from piston during removal.

DISASSEMBLY
1. Using a small screw driver, remove piston boot ring (slowly pry up one end of boot ring) and piston boot from caliper.





2. Remove piston from caliper body by applying low pressure, non-lubricated, compressed air into caliper inlet hole.

CAUTION: Pad interior of caliper body to provide a protective cushion for piston when it exits the caliper. This will protect piston from surface damage caused from piston/caliper body contact.





3. Remove piston seal from groove in caliper body.

CAUTION: To prevent damage to caliper body bore, use a small wooden or plastic (not metal) device to extract seal.





4. Remove bleeder valve and bleeder valve cap from caliper body.
5. Clean all parts in clean denatured alcohol. Dry with non-lubricated, low pressure, compressed air. Make sure to blow out all passages in caliper body and bleeder valve.
6. Inspect piston for scoring, nicks, cracks, wear or corrosion. Replace piston if any damage is found.
7. Inspect caliper body piston bore for scoring, nicks, wear, or corrosion. Crocus cloth can be used to remove light corrosion. If more extensive damage is present, replace the caliper.

CAUTION: Do not hone caliper bore.





8. Inspect seal groove in caliper bore for nicks or burrs. If present, replace caliper.





ASSEMBLY
1. Install bleeder valve into caliper body assembly.
^ Torque to 11 Nm (8 ft. lbs.)
2. Install bleeder valve cap.





3. Lubricate new piston seal with clean brake fluid and install seal into caliper seal groove.

NOTE: Make sure seal is not twisted.

4. Install lubricated piston boot onto piston.
5. Lubricate outside diameter of piston with clean brake fluid.





6. Install piston into caliper body. Push piston all the way to the bottom of the caliper bore.

CAUTION: Considerable force may be required to install piston.





7. Install boot ring.
a. Make sure that the outside edge of the piston boot is smoothly seated in counterbore of caliper body.
b. Work boot ring into groove near open end of caliper bore utilizing care not to pinch piston boot between boot ring and caliper body.
c. After installing boot ring, lift inner edge of piston boot to release any trapped air. The boot must lie flat, below the level of the piston face.