8/13/2019 Bao Duong Xe Airblade
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16. BRAKE SYSTEM
COMPONENT LOCATION16-2
SERVICE INFORMATION16-3
TROUBLESHOOTING16-5
REAR DRUM BRAKE 16-6
BRAKE FLUID REPLACEMENT/AIR BLEEDING 16-7
BRAKE PAD/DISC16-9
BRAKE MASTER CYLINDER16-12
COMBINED BRAKE EQUALIZER(CBS TYPE)16-16
BRAKE CALIPER 16-19
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BRAKE SYSTEM
16-2
BRAKE SYSTEM
COMPONENT LOCATIONFRONT DISC BRAKE
STANDARD TYPE
COMBINED BRAKE SYSTEM (CBS) TYPE
REAR DRUM BRAKE
34 Nm (3.5 kgfm, 25 lbfft)
30.4 Nm (3.1 kgfm, 22 lbfft)
34 Nm (3.5 kgfm, 25 lbfft)
34 Nm (3.5 kgfm, 25 lbfft)
30.4 Nm (3.1 kgfm, 22 lbfft)
34 Nm (3.5 kgfm, 25 lbfft)
118 Nm (12.0 kgfm, 87 lbfft)
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BRAKE SYSTE
16-
SERVICE INFORMATIONGENERAL
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts.Be careful whenever you remove the reservoir cap; make sure the master cylinder reservoir is horizontal first.
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc withigh quality brake degreasing agent.
Check the brake system by applying the brake lever after the air bleeding. Never allow contaminants (dirt, water, etc.) to get into an open reservoir. Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled. Always use fresh DOT 3 or DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types
fluid, they may not be compatible. Always check brake operation before riding the scooter.
SPECIFICATIONS
Unit: mm
Frequent inhalation of brake pad and shoe dust, regardless of material composition, could be hazardous to your heal Avoid breathing dust particles. Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
ITEM STANDARD SERVICE LIMIT
Brake lever freeplay 10 20 (0.4 0.8)
Brake drum I.D. 130.0 (5.12) 131.0 (5.16)
Specified brake fluid DOT 3 or 4
Brake disc Thickness 3.3 3.7 (0.13 0.15) 3.0 (0.12)
Warpage 0.10 (0.004)
Master cylinder Cylinder I.D. 12.700 12.743 (0.5000 0.5017) 12.755 (0.5022
Piston O.D. 12.657 12.684 (0.4983 0.4994) 12.645 (0.4978
Caliper Cylinder I.D. 25.400 25.450 (1.0000 1.0020) 25.460 (1.0024
Piston O.D. 25.318 25.368 (0.9968 0.9987) 25.31 (0.996)
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BRAKE SYSTEM
16-4
TORQUE VALUES
TOOL
Rear axle nut 118 Nm (12.0 kgfm, 87 lbfft) U-nut, Apply engine oil to the threadsand seating surface
Rear brake arm bolt 10 Nm (1.0 kgfm, 7 lbfft) ALOC bolt; replace with new one.
Brake caliper bleed valve 5.4 Nm (0.6 kgfm, 4.4 lbfft)
Brake master cylinder reservoir cap screw 1.5 Nm (0.2 kgfm, 1.1 lbfft)
Brake pad pin 18 Nm (1.8 kgfm, 13 lbfft)
Front brake lever pivot bolt(Standard type only) 1 Nm (0.1 kgfm, 0.7 lbfft)
Front brake lever pivot screw(CBS type only)
1 Nm (0.1 kgfm, 0.7 lbfft)
Front brake lever pivot nut 6 Nm (0.6 kgfm, 4.4 lbfft)
Front brake light switch screw 1 Nm (0.1 kgfm, 0.7 lbfft)
Brake hose oil bolt 34 Nm (3.5 kgfm, 25 lbfft)
Brake caliper mounting bolt 30.4 Nm (3.1 kgfm, 22 lbfft) ALOC bolt; replace with new ones.
Rear brake lever pivot screw(CBS type only)
4.2 Nm (0.4 kgfm, 3.1 lbfft)
Rear brake lever pivot nut(CBS type only)
5.2 Nm (0.5 kgfm, 3.8 lbfft) U-nut
Equalizer rod pivot screw(CBS type only)
4.2 Nm (0.4 kgfm, 3.1 lbfft)
Equalizer rod pivot nut
(CBS type only)
5.2 Nm (0.5 kgfm, 3.8 lbfft) U-nut
Rear brake lever bracket cover screw(CBS type only)
4.2 Nm (0.4 kgfm, 3.1 lbfft)
Rear brake lever bracket cover special screw(CBS type only)
4.2 Nm (0.4 kgfm, 3.1 lbfft)
Brake caliper torque pin 22 Nm (2.2 kgfm, 16 lbfft)
Brake caliper pin 18 Nm (1.8 kgfm, 13 lbfft)
Equalizer connecting cable lock nut(CBS type only)
6.4 Nm (0.7 kgfm, 4.7 lbfft)
Snap ring pliers
07914-SA50001
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BRAKE SYSTE
16-
TROUBLESHOOTINGPoor rear brake performance Incorrect adjustment of rear brake lever Contaminated brake shoes Worn brake shoes Worn brake cam Worn brake drum Improperly installed brake arm
Improperly engaged brake arm serrations
Brake lever soft or spongy Air in hydraulic system Leaking hydraulic system Contaminated brake pad/disc Worn caliper piston seals Worn master cylinder piston cups Worn brake pad/disc Contaminated caliper Contaminated master cylinder Caliper not sliding properly Low brake fluid level Clogged fluid passage Warped/deformed brake disc Sticking/worn caliper piston
Sticking/worn master cylinder piston Bent brake lever
Brake lever hard Clogged/restricted brake system Sticking/worn caliper piston Caliper not sliding properly Worn caliper piston seal Sticking/worn master cylinder piston Bent brake lever
Brake drags Contaminated brake pad/disc Misaligned wheel Badly worn brake pad/disc Warped/deformed brake disc
Caliper not sliding properly Clogged/restricted fluid passage Sticking caliper piston Improperly adjusted connecting cable (CBS type only)
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BRAKE SYSTEM
16-6
REAR DRUM BRAKEDISASSEMBLY/ASSEMBLY
Always replace the brake shoes as a set. Mark all parts during disassembly so they can be
placed back in the original locations.
Remove the rear wheel (page 15-5).
Remove the adjusting nut and brake cable from the jointpin.Remove the joint pin and return spring.
Expand the brake shoes and remove the brake shoes/shoe springs from the brake panel.Remove the following:
Brake arm bolt Brake arm/brake cam Dust seals
Install the removed parts in the reverse order ofremoval.
Apply grease to the new dust seals, brake camsliding surface and brake shoe contacting area.
Replace the dust seals and brake arm bolt with newones.
Adjust the rear brake lever freeplay (page 4-17).
TORQUE:BRAKE ARM BOLT
10 Nm (1.0 kgfm, 7 lbfft)
Set the return spring ends into the hole
on the left crankcase and onto the pin
on the brake arm.
DUST SEALS
BRAKE CAM BRAKE SHOES
RETURN SPRING
BRAKE ARM BOLT
10 Nm (1.0 kgfm, 7 lbfft)
SHOE SPRINGS
BRAKE ARM
ADJUSTING NUT
JOINT PIN
*: Apply each 0.2 - 0.3 g of grease.
*
*Align
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BRAKE SYSTE
16-
INSPECTION
Measure the rear brake drum I.D.
BRAKE FLUID REPLACEMENT/AIR BLEEDING
BRAKE FLUID DRAINING
Do not mix different types of fluid, as they are not
compatible with each other. Do not allow foreign material to enter the systemwhen filling the reservoir.
Spilled fluid can damage painted, plastic or rubberparts. Place a rag over these parts whenever thesystem is serviced.
Turn the handlebar until the reservoir is parallel to theground before removing the reservoir cap.
Remove the screws, reservoir cap, diaphragm plateand diaphragm.
Connect a bleed hose to the caliper bleed valve.
Loosen the bleed valve and pump the brake lever untilno more fluid flows out of the bleed valve.
SERVICE LIMIT: 131.0 mm (5.16 in)
RESERVOIR CAP
DIAPHRAGM
PLATEDIAPHRAGM
SCREWS
BLEED VALVE BLEED HOS
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BRAKE SYSTEM
16-8
BRAKE FLUID FILLING/AIR BLEEDING
Do not mix different
types of fluid. They
are not compatible.
Fill the master cylinder reservoir with DOT 3 or DOT 4brake fluid from the sealed container to the upper level.
Check the fluid level often while bleeding the braketo prevent air from being pumped into the system.
Connect a commercially available brake bleeder to thebleed valve.
Operate the brake bleeder and loosen the bleed valve.
If the brake bleeder is not available, perform thefollowing procedure.
Pump up the system pressure with the brake lever untilthe lever resistance is felt.
Check the fluid
level often while
bleeding the brake
to prevent air from
being pumped into
the system.
Do not release thebrake lever until the
bleed valve has
been closed.
Connect a bleed hose to the bleed valve and bleed thesystem as follows:
1. Squeeze the brake lever all the way and loosen thebleed valve 1/2 of a turn. Wait several seconds andthen close the bleed valve.
2. Release the brake lever slowly and wait several
seconds after it reaches the end of its travel.3. Repeat the steps 1 and 2 until there are no air
bubbles in the bleed hose.
After bleeding the system completely, tighten the bleedvalve to the specified torque.
UPPER LEVEL
If air enters the
bleeder from
around the bleed
valve threads, sealthe threads with
teflon tape.
Check the fluid level
often while bleeding
the brake to prevent
air from being
pumped into the
system.
BLEED VALVE
TORQUE:5.4 Nm (0.6 kgfm, 4.4 lbfft)
BLEED VALVE BLEED HOSE
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BRAKE SYSTE
16-
Do not mix different
types of fluid. They
are not compatible.
Fill the reservoir to the upper level with DOT 3 or DOT 4brake fluid from a sealed container.
Install the diaphragm, diaphragm plate and reservoircap, then tighten the screws to the specified torque.
BRAKE PAD/DISCBRAKE PAD REPLACEMENT
Check the brake
fluid level in the
reservoir as this
operation causes
the level to rise.
Push the caliper pistons all the way in to allowinstallation of new brake pads.
Remove the pad pin from the brake caliper.
Remove the O-ring from the pad pin.
UPPER LEVE
TORQUE:1.5 Nm (0.2 kgfm, 1.1 lbfft)
RESERVOIR CAP
DIAPHRAGM
PLATE DIAPHRAGM
SCREWS
BRAKE CALIPER
PAD PIN / O-RING
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BRAKE SYSTEM
16-10
Remove the brake pads from the brake caliper.
Always replace the
brake pads in pairs
to assure even disc
pressure.
Install new brake pads so that they are set on the brakecaliper bracket and bracket pin.
Apply silicon grease to the new O-ring and install it tothe pad pin.
Install the pad pin by pushing the brake pads againstthe pad spring to align the pad pin holes on the padsand caliper hole.
After the brake pad
replacement, check
the brake operation
by applying the
brake lever.
Tighten the pad pin to the specified torque.
BRAKE
PADS
BRAKE
PADS
Set the pads BRACKET PIN
PAD PIN
O-RING
TORQUE:18 Nm (1.8 kgfm, 13 lbfft)
PAD PIN
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BRAKE SYSTE
16-1
BRAKE DISC INSPECTION
Visually inspect the brake disc for damage or cracks.
Measure the brake disc thickness at several points.
Check the brake disc for warpage.
If the warpage exceeds the service limit, check thewheel bearings for excessive play.
For brake disc replacement, refer to page 14-8.
SERVICE LIMIT: 3.0 mm (0.12 in)
SERVICE LIMIT: 0.10 mm (0.004 in)
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BRAKE SYSTEM
16-12
BRAKE MASTER CYLINDERREMOVAL/INSTALLATION
STANDARD TYPE
Drain the brake fluid (page 16-7).Remove the rear handlebar cover (page 3-8).
Disconnect the front brake light switch wire (Green/
Yellow, Black) connectors.Remove the oil bolt, brake hose and sealing washers.
Install the removed parts in the reverse order ofremoval.
Replace the sealing washers with new ones. Fill and air bleed the hydraulic system (page 16-7).
CBS TYPE
Drain the brake fluid (page 16-7).
Remove the rear handlebar cover (page 3-8).Loosen the rear brake adjusting nut until the play of thebrake cable becomes maximum.
TORQUE:OIL BOLT
34 Nm (3.5 kgfm, 25 lbfft)
OIL BOLT
34 Nm (3.5 kgfm, 25 lbfft)
BRAKE HOSE
WIRE (Green/Yellow, Black)
CONNECTORS
MASTER CYLINDER
DIAPHRAGM
DIAPHRAGM PLATE
RESERVOIR CAP
SCREW
1.5 Nm (0.2 kgfm, 1.1 lbfft)BOLTS
SEALING WASHERS
Set the brake hose
eyelet against the
stopper.
Set the holder with
its "UP" mark facing
up.
Tighten the upper
bolt first, then the
lower bolt.
Align the end of master
cylinder with the punch
mark on handlebar.
HOLDER
ADJUSTING NUT
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BRAKE SYSTE
16-1
Loosen the lock nut and turn the adjuster until the playof the connecting cable becomes maximum.
Compress the return spring and disconnect the tip ofthe connecting cable from the knocker joint.Remove the return spring.Remove the connecting cable.
Remove the master cylinder (page 16-12).
Install the master cylinder (page 16-12).
Install the connecting cable to the master cylinder.Turn in the adjuster completely.Set the return spring on the connecting cable.Compress the return spring and connect the tip of theconnecting cable to the knocker joint.
Fill and air bleed the hydraulic system (page 16-7).
Turn the adjuster until the edge surface of the knockerseats on the edge surface of the master cylinder body.
Check that there is no gap between the knocker pin andthe end of the slot of the knocker joint.
If there is any gap, turn the adjuster until there is no gapbetween the knocker pin and the end of the slot of theknocker joint.
After adjustment, hold the adjuster and tighten the locknut to the specified torque.
After tightening the lock nut, check that there is no gapbetween the knocker pin and the end of the slot of theknocker joint.
Apply rear brake lever several times and check that thedistance between the edges has not been changedafter applying the brake.
Recheck the edge surface of the knocker seats on theedge surface of the master cylinder body.
Adjust the rear brake lever freeplay (page 4-17).Install the rear handlebar cover (page 3-8).
LOCK NUT
CONNECTING
CABLE
ADJUSTERRETURN
SPRING
KNOCKER
JOINT
INSPECTION
POINT
KNOCKER
ADJUSTER
CONNECTING
CABLE
RETURN
SPRING
TORQUE:6.4 Nm (0.7 kgfm, 4.7 lbfft)
KNOCKER JOINT
KNOCKER PIN
LOCK NUT ADJUSTER
INSPECTION
POINT
KNOCKER
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BRAKE SYSTEM
16-14
DISASSEMBLY/ASSEMBLY
STANDARD TYPE
Remove/install the following:
Brake lever pivot nut, bolt and brake lever Screw and brake light switch Boot
Remove/install the snap ring using the special tool.
Remove/install the washer, master piston and spring.
Keep the piston, cups, spring, snap ring and boot asa set; do not substitute individual parts.
When installing the cups, do not allow the lips to turn
inside out. Be sure that snap ring is firmly seated in the groove. Apply silicone grease to the pivot bolt sliding
surface, boots inside and lever to piston contactarea.
Apply brake fluid to master piston, piston cups andspring.
TOOL:
Snap ring pliers 07914-SA50001
TORQUE:FRONT BRAKE LEVER PIVOT BOLT
1 Nm (0.1 kgfm, 0.7 lbfft)
FRONT BRAKE LEVER PIVOT NUT
6 Nm (0.6 kgfm, 4.4 lbfft)
FRONT BRAKE LIGHT SWITCH SCREW
1 Nm (0.1 kgfm, 0.7 lbfft)
SNAP RING PLIERS
SNAP RING
BRAKE LEVER
PIVOT NUT
6 Nm (0.6 kgfm, 4.4 lbfft)SCREW
1 Nm (0.1 kgfm, 0.7 lbfft)
BRAKE LIGHT
SWITCH
MASTER
CYLINDER BODY
*: Apply 0.1 g of silicone grease
MASTER PISTON
SNAP RING
WASHER PISTON CUPS
SPRING
BOOT
PIVOT BOLT
1 Nm (0.1 kgfm, 0.7 lbfft)
*
(Lever contact area)
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BRAKE SYSTE
16-1
CBS TYPE
Remove/install the following:
Brake lever pivot nut/screw/brake lever/knocker/return spring/spring
Screw and brake light switch Boot
Remove/install the snap ring using the snap ring pliers(page 16-14).Remove/install the washer, master piston and spring.
Keep the piston, cups, spring, snap ring and boot asa set; do not substitute individual parts.
When installing the cups, do not allow the lips to turninside out.
Be sure that snap ring is firmly seated in the groove. Apply silicone grease to the pivot screw sliding
surface, boots inside and lever to piston contactarea.
Apply brake fluid to master piston, piston cups andspring.
INSPECTION
Check the piston cups for wear, deterioration ordamage.
Check the master cylinder inner surface and pistonouter surface for scratches or damage.
Measure the master cylinder I.D.
Measure the master piston O.D.
TORQUE:FRONT BRAKE LEVER PIVOT SCREW
1 Nm (0.1 kgfm, 0.7 lbfft)
FRONT BRAKE LEVER PIVOT NUT
6 Nm (0.6 kgfm, 4.4 lbfft)
FRONT BRAKE LIGHT SWITCH SCREW
1 Nm (0.1 kgfm, 0.7 lbfft)
BRAKE LEVER
PIVOT NUT
6 Nm (0.6 kgfm, 4.4 lbfft)SCREW
1 Nm (0.1 kgfm, 0.7 lbfft)
BRAKE LIGHT
SWITCH
MASTER
CYLINDER BODY
*: Apply 0.1 g of silicone grease
MASTER PISTON
SNAP RING WASHERPISTON CUPS
SPRINGBOOT PIVOT SCREW
1 Nm (0.1 kgfm, 0.7 lbfft)
KNOCKER
SPRING
RETURN
SPRING
*(Lever contact area)
SERVICE LIMIT: 12.755 mm (0.5022 in)
SERVICE LIMIT: 12.645 mm (0.4978 in)
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BRAKE SYSTEM
16-16
COMBINED BRAKE EQUALIZER(CBS TYPE)
REMOVAL/INSTALLATION
Remove the front handlebar cover (page 3-8).Disconnect the connecting cable (page 16-12).
Remove/install the following:
Special screw/set rubber Screws/bracket cover
Lock lever/return spring Bolt/holder/lever bracket Brake lever pivot screw/nut Equalizer rod pivot screw/nut Brake lever Brake cable/connecting cable Brake light switch/grommet
Apply grease to the pivot screws and equalizer sliding surface.
Be careful when
removing the lock
lever. The return
spring may pop out.
TORQUE:BRACKET COVER SCREW
4.2 Nm (0.4 kgfm, 3.1 lbfft)
BRACKET COVER SPECIAL SCREW
4.2 Nm (0.4 kgfm, 3.1 lbfft)
REAR BRAKE LEVER PIVOT SCREW4.2 Nm (0.4 kgfm, 3.1 lbfft)
REAR BRAKE LEVER PIVOT NUT
5.2 Nm (0.5 kgfm, 3.8 lbfft)
EQUALIZER ROD PIVOT SCREW
4.2 Nm (0.4 kgfm, 3.1 lbfft)
EQUALIZER ROD PIVOT NUT
5.2 Nm (0.5 kgfm, 3.8 lbfft)
BOOT GROMMET
SCREWS
4.2 Nm (0.4 kgfm, 3.1 lbfft)
BRAKE LEVER
HOLDER
BOLT
BRAKE LEVER BRACKET
SPECIAL SCREW
4.2 Nm (0.4 kgfm, 3.1 lbfft)
BRACKET
COVER
SET RUBBER
CONNECTING CABLE
EQUALIZER
BRAKE CABLE
BRAKE LIGHT SWITCH
BRAKE LEVER PIVOT SCREW
4.2 Nm (0.4 kgfm, 3.1 lbfft)
EQUALIZER ROD PIVOT SCREW
4.2 Nm (0.4 kgfm, 3.1 lbfft)
PIVOT NUTS
5.2 Nm (0.5 kgfm, 3.8 lbfft)
Install the spring as shown:
LOCK LEVER
RETURN
SPRING
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BRAKE SYSTE
16-1
Install the rear brake light switch while aligning its tabwith the groove on rear brake lever bracket.
Connect the brake light switch wire connectors.
Apply grease to the sliding surface of the equalizer.
Install the boot grommet over the equalizer.
Connect the rear brake cable to the equalizer with the"F" mark of the equalizer facing up and set the rearbrake cable to the rear brake lever bracket.Connect the connecting cable to the equalizer and setthe connecting cable to the rear brake lever bracket.
Install the equalizer boots grommet to the rear brakelever bracket.
Set the rear brake lever to the rear brake lever bracketand the equalizer.
Apply grease to the sliding surface of the rear brakelever pivot screw.Install and tighten the pivot screw to the specifiedtorque.
Apply grease to the sliding surface of the equalizer rodpivot screw.Install and tighten the pivot screw to the specifiedtorque.
Install and tighten the brake lever pivot nut to thespecified torque while holding the pivot screw.
Install and tighten the equalizer rod pivot nut to thespecified torque while holding the pivot screw.
Align the boss of the rear brake lever bracket with thehole of the handlebar and install the rear brake leverbracket.
Install the bracket holder onto the handlebar by aligningthe groove of the holder and tab of the lever bracket.
Alig
WIRE CONNECTORS
EQUALIZER
BOOT
GROMME"F" MARKCONNECTING CABLE
BRAKE
CABLE
TORQUE:4.2 Nm (0.4 kgfm, 3.1 lbfft)
TORQUE:4.2 Nm (0.4 kgfm, 3.1 lbfft)
TORQUE:5.2 Nm (0.5 kgfm, 3.8 lbfft)
TORQUE:5.2 Nm (0.5 kgfm, 3.8 lbfft)
NUTS BRAKE LEVER
EQUALIZER ROD
PIVOT SCREWBRAKE LEVE
PIVOT SCREW
BRACKET HOLDER
Align
(Tab and hole)
Align (Boss and hole)
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BRAKE SYSTEM
16-18
Install and tighten the holder bolt.
Set the return spring to the rear brake lock lever.Install the rear brake lock lever to the rear brake leverbracket and make sure that the return spring is set inposition as shown.
Set the bracket cover to the rear brake lever bracketwhile holding the rear brake lock lever.Tighten the bracket cover screws to the specifiedtorque.
Install the set rubber to the rear brake lock lever andtighten the bracket cover special screw to the specifiedtorque.
Check the brake lock lever operation (page 4-20).Connect the connecting cable (page 16-12).
Install the front handlebar cover (page 3-8).
HOLDER BOLT
LOCK LEVER
RETURN SPRING
TORQUE:4.2 Nm (0.4 kgfm, 3.1 lbfft)
SCREWS
BRACKET COVER LOCK LEVER
TORQUE:4.2 Nm (0.4 kgfm, 3.1 lbfft)
SET RUBBER SPECIAL SCREW
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BRAKE SYSTE
16-1
BRAKE CALIPERREMOVAL
Avoid spilling fluid
on painted, plastic,
or rubber parts.
Place a shop towel
over these parts
whenever thesystem is serviced.
Drain the brake fluid (page 16-7).
Remove the following:
Oil bolt/sealing washers Brake pads (page 16-9)
Mounting bolts Brake caliper
INSTALLATION
Install the front brake caliper onto the left fork leg.Install new mounting bolts and tighten them to thespecified torque.
Connect the brake hose to the brake caliper with the oilbolt and new sealing washers.
Tighten the oil bolt to the specified torque.
Install the brake pads (page 16-9).Fill the brake fluid and bleed the hydraulic system (page16-7).
TORQUE:30.4 Nm (3.1 kgfm, 22 lbfft)
Tighten the oil bolt
while pushing the
brake hose eyelet
joint against thestopper.
TORQUE:34 Nm (3.5 kgfm, 25 lbfft)
BRAKE CALIPER
BRAKE HOSE
SEALING WASHERS
BRAKE CALIPER MOUNTING BOLTS
30.4 Nm (3.1 kgfm, 22 lbfft)
OIL BOLT
34 Nm (3.5 kgfm, 25 lbfft)
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BRAKE SYSTEM
DISASSEMBLY/ASSEMBLY
Remove the following:
Caliper bracket Pin boots Pad spring
Place a shop towel over the piston.
Position the caliper body with the piston facing down
and apply small squirts of air pressure to the fluid inletto remove the piston.
Remove the dust seal/piston seal.
Install the removed parts in the reverse order ofremoval.
Apply silicone grease to the dust seal and bracketpin boots.
Apply brake fluid to the piston and piston seal. Replace the dust seal and piston seal with new ones.
INSPECTION
Check the caliper cylinder for scoring, scratches or
damage.Measure the caliper cylinder I.D.
Check the caliper piston for scoring, scratches ordamage.
Measure the caliper piston O.D.
Do not use high
pressure air or bring
the nozzle too close
to the inlet.
BLEED VALVE
5.4 Nm (0.6 kgfm, 4.4 lbfft)
CALIPER BODY
*: Apply 0.4 g minimum of silicone grease
CALIPER PISTON
PAD SPRING
BRACKET PIN BOOT
PISTON SEAL
CALIPER BRACKET
DUST SEAL
BRACKET PIN BOOT
Install the caliper piston with
its opened end facing the
brake pads.
*
*
SERVICE LIMIT: 25.460 mm (1.0024 in)
SERVICE LIMIT: 25.31 mm (0.996 in)
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