Replacing Rubber Parts Of Calipers - Benelli TNT 25 Maintenance Manual

Replacing Rubber Parts of Calipers

Disassembling Front Calipers
●Before the front calipers are disassembled, drain the front brake
fluid.
●Loosen the front calipers mounting bolt [A] and banjo bolt [B], and
then gently unscrew them.
●Removing:
Front calipers [C] (see "Disassembling Front Calipers" in the "Brake"
chapter),
Front brake pad (see "Disassembling Front Brake Pad" in the "Brake"
chapter),
Front calipers assembling bolt
O-ring seal
●Remove the piston by using the compressed air.
A piston removal method is shown below:
○Install a rubber gasket [A] and a wood board [B] with thickness of
more than 10 mm (0.4 in.) in the middle of the calipers. Fix the
rubber gasket and wood board together with appropriate bolts and
nuts as shown in the figure. Keep one of the oil passage open[C].
○Slowly inject the compressed air [D] into the oil passage until the
piston touches the rubber gasket. If the calipers are in a half-open
condition, the hose joint [E] shall be blocked during operation.
Press the bolt [F] and nut: [G].
Warning
In order to avoid serious injury, do not put your finger or palm
in front of the piston! Otherwise, the piston will crush the hand
or finger when the compressed air is injected into the calipers.
○Pull out the piston with hands.
●Remove the dust seal [A] and oil seal [B].
●Repeat the above steps and remove the piston from the other side
of calipers body.
Remark
○If the compressed air cannot be used, remove the piston from the
two calipers according to the following method (the brake hose is
connected with the calipers).
○Prepare a container to contain the brake fluid.
○Remove the brake pad spring and brake pad (see "Disassembling
Front Brake Pad" in the "Brake" chapter).
○Press the brake rod until the piston is pushed out of the brake
caliper and then remove the calipers.
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