Front Brake Calliper Removal; Front Brake Calliper Overhaul - PIAGGIO NRG Power DT Workshop Manual

Braking system
Front brake calliper
Removal
•
Check that the brake piping, gasket
and fitting are in good condition. If you
see any oil on the brake calliper and/on
the components of the system, it is
necessary to replace them.
•
- Disconnect the oil line from the cal-
liper, collecting the oil in a container.
•
- Remove the two clamps highlighted
in the diagram.
Overhaul
- Remove the calliper assembling bolts and take out the internal bodies and components. If necessary,
in order to make it easier to take out the plungers, inject (shorts blasts of) compressed air through the
brake fluid pipe.
- Check that the cylinders of the internal and external body of the calliper do not show scratches or signs
of erosion; otherwise, replace the entire calliper.
CAUTION
ALL THE INTERNAL COMPONENTS MUST BE REPLACED EVERY TIME THE CALLIPER IS
SERVICED.
Insert the following: - sealing rings (1-2);
- pistons (3);
- locate the OR seal inside a calliper body (4).
- Join the inner and outer bodies via fixing bolts. Refit the pads and breathe any air inside the circuit
(see previous paragraphs).
- Locate the calliper on the disc and secure to the supporting bracket tightening the fixing bolt.
- Tighten the tube joint on the calliper at the prescribed torque.
- When refitting the components, they must be perfectly clean and free from any trace of oil, fuel, grease,
etc... It is therefore necessary to carefully clean them with denatured alcohol.
The seal rings must be immersed in the operating liquid; Protective solution PRF1 may be used.
CAUTION
RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL FOR LONGER THAN 20 SECONDS.
AFTER WASHING, THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A
CLEAN CLOTH.
Locking torques (N*m)
Calliper coupling screw 20 to 25 Nm Oil bleed screw 7 to 10 Nm
BRAK SYS - 2
NRG Power DT