BOMBARDIER RALLY 200 2003 Shop Manual page 259

Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
Disassembly
Remove brake pads, see the following section.
Remove boot kit no. 12 and pad spring.
Place rag over piston.
Place caliper body with piston down and apply
small squirts of air pressure to the fluid inlet to re-
move piston.
WARNING
Do not use high pressure air or bring nozzle too
close to inlet.
Remove piston seal.
CAUTION: Be careful not to damage piston
sliding surface.
Clean piston grooves, caliper cylinder and piston
with clean brake fluid.
Clean slide pins with brake cleaner and a rag.
Inspection
If boots no. 3 are deteriorated or hard, replace
with new ones.
Check caliper cylinder for scratches, rust or other
damage. If so, replace caliper.
Check piston for scratches, rust or other damage.
If so, replace piston.
Assembly
Coat piston seal with clean brake fluid and install
it into piston grooves in caliper.
Coat piston with clean brake fluid and install into
cylinder with the closed end toward caliper body.
Apply silicone grease into sliding bores and install
slide pins.
NOTE: Make sure that rubber boots are correctly
installed in slide pins grooves.
Install pad spring, caliper bracket and pads.
Installation
For the installation, reverse the removal procedure,
pay attention to the following details.
Use new sealing washers when installing Banjo bolt
retaining brake hose to caliper.
CAUTION: In case of replacing the bolts no. 11,
replace it with the same length bolts only. Install-
ing longer bolts can damage brake disc and front
brake assembly.
09-02-6
1. Brake disc
2. Bolt
Make sure that the pad spring is installed in the right
position.
1. Pad spring
Install caliper to knuckle.
If hose was disconnected, bleed the brakes.
Check for leaks and make sure the brakes operate
normally before driving.
VMR2003_028_09_02A.FM