Apply brake fluid to the new parts and to the inner wall of
Take care not to scratch the piston or the inner wall of the
Tighten the brake lever pivot bolt and the locknut.
Apply silicone grease:
Brake Lever Pivot Bolt
Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 9
Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60
kgf·m, 52 in·lb)
Caliper Rubber Parts Replacement
Front Caliper Disassembly
Loosen the front caliper pad pins [A] and banjo bolt [B]
and tighten them loosely.
Front Caliper (see Front Caliper Removal in the Brakes
Front Caliper Assembly Bolts
Using compressed air, remove the pistons. One way to
remove the pistons is as follows.
Install a rubber gasket [A] and a wooden board [B] more
than 10 mm (0.4 in.) thick on the caliper half, and fas-
ten them together with a suitable bolt and nut as shown.
Leave one of the oil passages [C] open.
Lightly apply compressed air [D] to the oil passage until
the pistons hit the rubber gasket. Block the hose joint
opening [E] during this operation if the caliper half has
Bolt and Nut [F]
Oil Passage Sealed by Rubber Gasket [G]
Push down [H].
To avoid serious injury, never place your fingers or
palm in front of the piston. If you apply compressed
air into the caliper, the piston may crush your hand
Pull out the pistons by hand.
Remove the dust seals [A] and fluid seals [B].
Repeat the previous step to remove the pistons from the
other side of the caliper body.
PERIODIC MAINTENANCE 2-57