Gilera Nexus 500, Workshop Manual, Page: 317 / 406

- Remove the two pistons from the calliper body
with the aid of small blasts of compressed air
through the brake fluid feeding hole. A piece of
rubber pipe may be needed to seal with the com-
pressor gun.
N.B.
PAY ATTENTION WHEN THE PISTONS COME
OUT AS THE STRONG BLASTS OF COM-
PRESSED AIR CAN MAKE THE PISTONS
COME OUT OF THE PUMP BODY VIOLENTLY
- Remove the dust-cover ring « A » and the sealing
ring « B » of each piston.
N.B.
DO NOT SCRATCH THE SEATS WHILE RE-
MOVING THE RINGS.
- Check that the pistons and relevant seats exhibit
no scratches.
- Wash only with alcohol and blow all the compo-
nents carefully.
- Fit new sealing rings and dust guards.
- Assembly the pistons into the appropriate seats
being careful to lubricate the sealing ring « B » with
brake fluid. The dust guard ring « A » has an inter-
nal groove with specific grease.
- Decouple the floating support of the calliper body
separating the 2 rubber dust-covers off their seats.
N.B.
TO EXTRACT THE LONG DUST-COVER PULL
IT BY ITS HEAD AND INTRODUCE THE BEL-
LOWS ( LOCATED ON THE OTHER SIDE) INTO
THE CALLIPER HOLE. LUBRICATE THE SLID-
ING PINS WITH SPECIFIC GREASE (APPRO-
PRIATE FOR RUBBER GASKETS).
- Once the cleaning and replacement operations have been performed, reassemble all the parts in the
reverse order followed during the removal.
N.B.
Nexus 500
Braking system
BRAK SYS - 7