Overhaul

DISASSEMBLY
1. Using a small screw driver, remove piston boot ring (slowly pry up one end of boot ring) and piston boot from caliper.

Fig. 5 Rear Caliper Piston Removal:

2. Remove piston from caliper body by applying low pressure, nonlubricated, compressed air into caliper inlet hole.

WARNING: To prevent bodily injury; make sure to keep fingers or other body parts away from piston during removal.

CAUTION: Pad interior of caliper body to provide a protective cushion for piston when it exits the caliper. This will protect piston from surface damage caused from piston/caliper body contact.

Fig. 6 Rear Caliper Piston Installation:

NOTE: An alternate method to using compressed air to extract the pistons is to use a brake piston driver type tool (SA9111ONE or equivalent) in the piston slots to rotate the piston counterclockwise, thereby threading the piston out of its bore.

3. Remove piston seal from groove in caliper body.

CAUTION: To prevent damage to caliper body bore, use a small wooden or plastic (not metal) device to extract seal.





4. Remove bleeder valve and bleeder valve cap from caliper body.





5. Only if replacing lever return spring:
a. Use screwdriver to disengage return spring from lever.
b. Unhook spring from stopper pin.
6. Clean all parts in clean denatured alcohol. Dry with non-lubricated, low pressure, compressed air. Make sure to blow out all passages in caliper body and bleeder valve.





7. Inspect piston for scoring, nicks, cracks, wear or corrosion. Replace piston if any damage is found.
8. Inspect caliper body piston bore for scoring, nicks, wear or corrosion. Crocus cloth can be used to remove light corrosion. If more extensive damage is present, replace the caliper.

CAUTION: Do not hone caliper bore.

9. Inspect seal groove in caliper bore for nicks or burrs. If present, replace caliper.

ASSEMBLY
1. Install bleeder valve into caliper body assembly.
^ Torque to 11 Nm (8 ft. lbs.)
2. Install bleeder valve cap.
3. Lubricate new piston seal with clean brake fluid and install into caliper seal groove.

NOTE: Make sure seal is not twisted and that outer lip of seal faces out.





4. Install lubricated piston boot onto piston.





5. Lubricate outside diameter of piston with clean brake fluid.
6. Install piston into caliper body.
a. Start piston into bore by hand.
b. Use SA91110NE (or equivalent type) tool in the piston slots to rotate the piston clockwise, thereby threading the piston into its bore.
c. Position piston indentation slots as shown.





7. Install boot ring.
a. Make sure that the outside edge of the piston boot is smoothly seated in counterbore of caliper body.
b. Work boot ring into groove near open end of caliper bore utilizing care not to pinch piston boot between boot ring and caliper body.
c. After installing boot ring, lift inner edge of piston boot to release any trapped air. The boot must lie flat, below the level of the piston face.





8. Install new lever return spring (if replaced).
a. Position spring with hook end around stopper pin.
b. Pry other end of spring over lever.