Brake Caliper Assembly - Honda XL200 2001 Shop Manual

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Push the dust and piston seals in an lift them out.
Clean the seal groove with clean brake fluid.
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• Be careful not to damage the piston sliding surface.
INSPECTION
Check the caliper pistons for scoring or other damage.
Measure the caliper piston O.D.
SERVICE LIMIT: 26.89 mm (1.0587 in)
Check the caliper cylinder bores for scoring or other damage.
Measure the caliper cylinder inside diameter.
SERVICE LIMIT: 27.06 mm (1.065 in)
ASSEMBLY
Coat the new piston seals and dust seals with clean brake fluid
and install them in the seal grooves of the caliper.
Lubricate the caliper cylinders and pistons with clean brake fluid
and install the pistons into the caliper cylinders with the closed
end of the piston facing the pad side.
Apply silicone grease to the pivot boots and install them making
sure that they are seated in the caliper and bracket grooves
properly.
Install the pad retainer on the caliper bracket.
Coat the caliper and bracket pins silicone grease.
Assemble the caliper bracket.
HYDRAULIC BRAKE
PISTON SEAL
DUST SEAL
CALIPER
PISTON
CALIPER
DUST SEAL PISTON
CALIPER
PISTON SEAL
BRACKET
PIN
1 3 -9