Removal
1. Remove the front wheel.
2. Remove the hollow bolt and disconnect the brake hose from the caliper.
Caution: To prevent brake fluid from leaking, close the hole in the brake hose with a suitable plug.
3. Remove the caliper mounting bolts.
4. Remove the caliper and brake pads.
5. Remove the bolts securing the caliper holder to the steering knuckle.
6. Remove the caliper mounting element.
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 the bushing and guide pin for damage and rust.
4. Check the spring and covers for damage.
5. Check the fastener for wear, damage, cracks and rust.
- 1. Do not use sandpaper to clean the piston surface.
- 2. All rubber parts must be replaced with new ones.
6. Measure the thickness of the brake disc. Using a dial indicator, measure the runout of the brake disc at a short distance from the outer edge.
Brake disc thickness:
- Nominal: 24 mm
- Minimum allowable: 22.4 mm
- Maximum permissible runout: 0.08 mm
- Maximum permissible difference in brake disc thickness: 0.01 mm
- 1. Using a micrometer, measure the thickness of the disc in eight places, approximately every 45° at a distance of 10 mm from the outer edge of the disc.
- 2. Use a dial indicator to check the runout of the brake disc. Attach a dial indicator in any convenient place and, by turning the brake disc, determine its runout at a distance of 5 mm from the outer edge.
7. If necessary, replace the brake disc.
Disassembly
1. Remove the piston dust cover.
2. Use compressed air to push the piston out of the caliper cylinder.
- 1. When pushing the piston out with compressed air, do not place your fingers in front of the piston.
- 2. Be careful, as the brake fluid will be blown out of the channel by compressed air along with the piston.
3. Using a screwdriver blade, remove the sealing ring from the piston.
Assembly
1. Clean all parts except the brake pads with isopropyl alcohol.
2. Apply special grease to the piston sealing ring and install it into 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 boot as shown in the figure;
- insert the piston boot into the inner groove of the caliper and push 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 into the bushing hole and install protective covers;
- insert the covers into the caliper grooves.
5. Install the brake pads.
Caution: Never apply grease to the brake disc or brake pads.
6. Screw in and tighten the hollow brake hose mounting bolt to the required tightening torque.
Tightening torques:
- Guide pin: 35–45 N·m
- Guide Pin Mounting Bolt: 22–33 Nm
- Caliper mounting bolt: 65–75 N·m
- Brake hose retaining bolt: 25–30 N·m
1. Before installation, check that the surfaces of the bolts and guide pin are not damaged.
2. Remove air from the hydraulic drive of the brake system. Press the brake pedal several times and check for brake fluid leaks.
Installation
Installation is carried out in the reverse order of removal.
1. Install the brake pads and caliper. Never apply grease to the brake disc or brake pads.
2. Screw in and tighten the caliper mounting bolt to the required tightening torque.
3. Screw in and tighten the hollow brake hose mounting bolt to the required tightening torque.
4. Pour brake fluid into the reservoir. Remove air from the hydraulic drive of the brake system. Press the brake pedal several times and check for brake fluid leaks.