Disassembly - Triumph 2012 Tiger 800 Service Manual

Disassembly

I
To prevent injury, never place fingers or hands inside
the caliper opening when removing the pistons. Always
wear eye, hand and face protection when using
compressed air. Eye, face and skin damage will result
from direct contact with compressed air.
1. Separate the caliper and mounting bracket.
2. Cover the caliper opening with a clean, heavy cloth
and, using either compressed air or by reconnecting
the master cylinder and pumping the brake lever,
eject both pistons from the caliper at the same time.
1. Dust seals
2. Piston seals
3. Pistons
Ensure the seal g rooves in the caliper bores are not
damaged during the removal of the seals. Damage to
the seal grooves may allow brake fluid to leak past the
seals resulting in a dangerous riding cond ition leading to
loss of motorcycle control and an accident.
3 . Extract the dust seals a n d piston seals, taking care
not to damage the caliper bores.
4.
Check the pistons, caliper and mounting bracket for
signs of damage, paying particular attention to the
caliper bores and pistons. If damage is present,
renew the worn com ponent or the complete caliper
assembly.
5. If all components are serviceable, obtain a piston seal
kit and reassemble the caliper as follows:
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SeiVice Manual Tiger 800 and Tiger 800XC
Always renew caliper seals after removal of the pistons.
An effective hyd raulic seal can only be made if new seals
are fitted.
A dangerous riding condition leading to an accident
could result if this warning is ignored.
'
Before installation, all internal brake com ponents should
be cleaned and lubricated with clean new DOT 4 brake
flu id.
Never use solvents, petrol (gasoline>, engine oil, or any
other petroleum distillate on internal brake components
as this will cause deterioration of the hydraulic seals in
the calipers and master cylinders.
A dangerous riding condition leading to loss of
motorcycle control and an accident could result if this
warning is ignored.
Ensure all com ponents are clean, t hen fit the new
6.
seals to their grooves in the caliper bores.
Z Lubricate the fluid seals, caliper bore and the outside
of the pistons with clean DOT 4 brake fluid.
8.
Ease the pistons squarely back into the bores, taking
care not to displace the seals.
Never use mineral based grease <such as lithium or
copper based grease) in any area where contact with the
braking system hydraulic seals and dust seals is possible.
Mineral based grease will damage the hydraulic seals
and dust seals in the calipers and master cylinders.
Damage caused by contact with mineral based grease
may reduce braking efficiency resulting in an accident.
Brakes
14.17