Disassembly and Assembly
DISASSEMBLY17-INCH TYPE
1) Remove mud and foreign matter from the caliper body.
CAUTION:
Be careful not to allow foreign matter to enter the brake hose connector.
2) Remove the piston boots from each piston end.
3) Place a wooden block in the caliper body as shown in the figure to prevent the piston from jumping out and being damaged.
4) Gradually apply compressed air via the brake hose installation hole to push the piston out.
5) Remove the piston seal (1) from the caliper body cylinder.
CAUTION:
Do not damage the cylinder and piston seal groove.
16-INCH TYPE
1) Remove mud and foreign matter from the caliper body and the support.
CAUTION:
Be careful not to allow foreign matter to enter the brake hose connector.
2) Place a wooden block in the caliper body as shown in the figure to prevent the piston from jumping out and being damaged.
3) Gradually apply compressed air via the brake hose installation hole to push the piston out.
4) Remove the piston boot.
5) Remove the piston seal (1) from the caliper body cylinder.
CAUTION:
Do not damage the cylinder and piston seal groove.
6) Remove the guide pin and boot from caliper body.
ASSEMBLY
17-INCH TYPE
1) Clean the inside of the caliper body using brake fluid.
2) Apply a coat of brake fluid to piston seal and install the piston seal to the caliper body groove.
3) Apply a coat of brake fluid to the inner surface of cylinder and the entire outer surface of the piston.
4) Apply NIGLUBE RX-2 (Part No. K0779AG102) or the piston kit grease to the boot, and install to the piston groove.
5) Insert the piston into the cylinder.
CAUTION:
Do not force the piston into cylinder.
6) Position the boot in the grooves on cylinder and piston.
16-INCH TYPE
1) Clean the inside of the caliper body using brake fluid.
2) Apply a coat of brake fluid to piston seal and install the piston seal to the caliper body groove.
3) Apply a coat of brake fluid to the inner surface of cylinder and the entire outer surface of the piston.
4) Apply grease contained in the piston seal kit to the boot, and install it to the groove at the end of the cylinder.
5) Insert the piston into cylinder.
CAUTION:
Do not force the piston into cylinder.
6) Position the boot in the grooves on cylinder and piston.
7) Apply a coat of the grease included with the piston kit to the lock pin and guide pin outer surface, cylinder inner surface, and boot grooves.
8) Insert the lock pin and guide pin boot into the support.
CAUTION:
After inserting the pin into the given place, move the caliper by hand to make sure that it moves smoothly without obstacles or excessive friction.
