Disassembly and Assembly
Front Disc Brake AssemblyDISASSEMBLY
CAUTION:
Be careful not to allow foreign matter to enter the brake hose connector.
1) Remove mud and foreign matter from the caliper body.
2) Remove the piston.
(1) Place a wooden block in the caliper body as shown in the figure to prevent the piston from jumping out and being damaged.
(2) Using an air gun, gradually apply compressed air via the brake hose installation hole to push the piston out.
3) Remove the piston boot from caliper body cylinder.
4) Remove the piston seal from caliper body cylinder.
CAUTION:
Do not damage the cylinder and piston seal groove.
5) Remove the guide pin, lock pin, bushing pin, and pin boot from the support.
ASSEMBLY
1) Before assembly, check each part.
2) Clean the inside of the caliper body cylinder using brake fluid.
3) Apply a coat of brake fluid to piston seal and install the piston seal to the caliper body cylinder groove.
4) Apply a coat of brake fluid to the inner surface of caliper body cylinder and the entire outer surface of the piston.
5) Apply grease contained in the piston seal kit to the piston boot, and install it to the groove at the end of the cylinder.
6) Insert the piston into caliper body cylinder.
CAUTION:
Do not force the piston into caliper body cylinder.
7) Position the piston boot in the grooves on caliper body cylinder and piston.
8) Apply grease contained in the piston seal kit to the lock pin, guide pin outer surface, support cylinder inner surface, and pin boot grooves.
9) Install the pin boot to the lock pin and guide pin, and insert it into the support cylinder.
CAUTION:
Insert the lock pin and guide pin into specified position, and make sure that they slide and seat properly.
