Withdrawal
1. Remove the front wheel.
2. Turn out a hollow bolt and disconnect a brake hose from a support.
Warning! To prevent leakage of brake fluid, close the hole in the brake hose with a suitable plug.
3. Turn out bolts of fastening of a support.
4. Remove the caliper and brake pads.
5. Remove the caliper holder mounting bolts (2EA) to the steering knuckle.
6. Remove the caliper fastener.
Disassembly
1. Remove the piston dust cover.
2. Press the piston out of the caliper cylinder with compressed air.
Warning! When pushing the piston out with compressed air, do not place your fingers in front of the piston.
Warning! Be careful, as brake fluid is blown out of the channel with compressed air along with the piston.
3. Use a screwdriver blade to remove the o-ring from the piston.
Examination
1. Check the caliper for wear, damage, cracks and rust.
2. Check the piston for rust, damage, cracks and wear on the outer surface.
3. Check bushing and guide pin for damage and rust.
4. Check the spring and boots for damage.
5. Check the fastener for wear, damage, cracks and rust.
Warning! Do not use sandpaper to clean the piston surface.
Warning! All rubber parts must be replaced with new ones.
6. Measure the brake disc thickness. Using a dial gauge, measure the runout of the brake disc a short distance from the outer edge.
Brake Disc Thickness:
- Rated: 19 mm
- Minimum allowable: 17 mm
- Maximum allowable runout: 0.05 mm
7. If necessary, replace the brake disc.
Assembly
1. Clean all parts except the brake pads with isopropyl alcohol.
2. Apply special grease to the piston o-ring and install it in the piston groove.
3. Assemble the piston and piston boots in the following order:
- apply special grease to the walls of the caliper cylinder, the outer surface of the piston and the piston boot;
- install the piston cover as shown in the figure;
- insert the piston boot into the inner groove of the caliper and slide the piston into the caliper.
4. Assemble the moving parts in the following order:
- apply special grease to the outer surface of the bushing, guide pin and bushing hole and install the protective covers;
- insert the covers into the grooves of the caliper.
5. Install the brake pads.
Warning! Never apply grease to the brake disc and brake pads.
6. Screw in and tighten the hollow bolt of fastening of a brake hose with the demanded moment of an inhaling.
Tightening torques:
- Guide pin: 34–44 Nm
- Sliding bolt: 22–31 Nm
- Caliper mounting bolt: 64–74 Nm
- Brake hose hollow bolt: 25–29 Nm
Warning! Before installation, check that the surfaces of the bolts and guide pin are not damaged.
Warning! Remove air from the hydraulic drive of the brake system. Depress the brake pedal several times and check for brake fluid leakage.