Brake Caliper Removal; Brake Caliper Disassembly; Front Master Cylinder Installation - Honda XL200 2001 Shop Manual

HYDRAULIC BRAKE
INSTALLATION
Place the master cylinder on the handlebar and install the holder
and two mounting bolts with holder's "UP" mark facing up.
Align the end of the holder with the punch mark on the
handlebar, then tighten the upper bolt first, then the lower bolt.
TORQUE: 10 N.m (1.0 kg.m, 7 ft-lb)
Connect the brake hose eyelet joint with a new sealing washers
and tighten the oil bolt to the specified torque.
TORQUE: 35 N.m (3.5 kg.m, 25 ft-lb)
Fill the master cylinder to the proper level and bleed the brake
system.
BRAKE CALIPER
REMOVAL
h
• Avoid spilling fluid on painted, plastic or rubber parts. Place
a shop towel over these parts whenever the system is
serviced.
Drain the brake fluid from the hydraulic system.
Remove the brake pads.
Place a clean container under the caliper and remove the oil
bolt, sealing washer and eyelet joint from the caliper.
Remove the brake caliper bracket bolts, then remove the brake
caliper and bracket as an assembly.
DISASSEMBLY
Remove the following:
– Caliper bracket
– Brake pad retainer
– Pad spring
– Caliper/bracket pin boot
– Pistons from caliper cylinder
If necessary, lightly apply compressed air to the caliper fluid inlet
to get the piston out.
Place a shop rag under the caliper to cushion the piston when it
is expelled.
Use the air in short spurts.
t
• Do not bring the air nozzle too close to the inlet or the
pistons may be forced out with excessive force that could
cause injury.
1 3 -8
MASTER CYLINDER PUNCH MARK BOLTS
BOLT SEALING WASHER
CALIPER
BOLT
BOOT
CALIPER
CALIPER
XL2 0 0
EYELET JOINT
SEALING WASHER
BRACKET
BOOT