Installation
1. Lower the caliper over the brake disc and seat it
on the caliper bracket.
2. Install the caliper mounting bolts (C,
Figure 55
).
Apply a medium-strength threadlocking compound
to the bolt threads and torque the caliper mounting
bolts to 40 N•m (30 ft.-lb.).
3. Install the brake pads as described in Steps 7-14
of
Rear Brake Pad Replacement
in this chapter.
4. Secure the brake hose to the caliper with the
banjo bolt (B,
Figure 55
). Place new washers on ei-
ther side of the brake hose fitting, and torque the
banjo bolt to 30 N•m (22 ft.-lb.). Note to the follow-
ing:
a. The stop washer (A,
Figure 55
) must sit be-
tween the caliper and the hose fitting.
b. The upper stop on the washer must sit against
the outboard side of the caliper indexing post.
c. The brake hose neck must rest against the in-
board side of the washer’s lower stop (A,
Fig-
ure 55
).
5. Secure the brake hose to the swing arm with the
cable holder (
Figure 54
).
6. Add brake fluid to the master cylinder and bleed
the brakes as described earlier in this chapter.
Disassembly
Refer to
Figure 53
.
1. Remove the caliper and the brake pads as de-
scribed in this chapter.
2. Set the caliper on a bench with the outboard side
facing down.
3. Insert a piece of wood through the calipers and
press the wood down against the outboard piston
(
Figure 56
).
WARNING
In the next step, the piston may shoot
out of the caliper body with great
force. Keep your fingers out of the
way. Wear shop gloves and apply air
pressure gradually.
4. Apply compressed air through the brake hose
fitting and blow the inboard piston out of its cylin-
der. Remove the piston from the caliper. Clearly la-
bel the piston so it can be reinstalled in its original
cylinder in the caliper.
5. Turn the caliper so the outboard side faces up.
Insert a rubber plug into the cylinder on the inboard
side of the caliper. If a plug is not available, use a
piece of rubber or wood that is large enough to
cover the inboard cylinder.
6. Insert a piece of wood through the caliper and
press the wood against the inboard cylinder. Apply
compressed air to the brake hose fitting and blow
the outboard piston (A,
Figure 57
) out of its cylin-
der.
BRAKES
369
13
54
55
56
