Brake Caliper Overhaul - Front

Disassembly Procedure

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





Caution

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

Notice

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.

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





Notice

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

3. Remove the piston seal from the groove in the caliper body.




4. Remove the bleeder valve and the bleeder valve cap from the caliper body.
5. Clean all the parts in clean denatured alcohol. Dry with non-lubricated, low pressure, compressed air. Make sure to blow out all passages in the caliper body and the bleeder valve.
6. Inspect the piston for scoring, nicks, cracks, wear or corrosion. Replace the piston if any damage is found.




7. Inspect the 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.

Important

Do not hone the caliper bore.

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

Assembly Procedure

Notice

Refer to Fastener Notice in Cautions and Notices.





1. Install the bleeder valve into the caliper body assembly.
Tighten

Tighten the front brake bleeder valve to 11 N·m (8 lb ft).

2. Install the bleeder valve cap.





Important

Make sure the seal is not twisted.

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




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

Important

Considerable force may be required to install the piston.

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





Important

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