Overhaul; Removing The Rear Caliper; Replacing The Rear Caliper; Rear Caliper Disassembly - Malaguti Password 250 i.e. Workshop Manual

FRAME AND RUNNING GEAR
A
5

OVERHAUL

• Undo screws (V2).
V
2
• Apply a low pressure jet of compressed air to the oil-
way in which the brake fluid union was fitted in order to
cause the two plungers to be ejected from the brake
calliper body.
Excessive air pressure will result in exces-
sively violent ejection of the two plungers
(A).
• Remove wiper seal ring (B) and oil seal ring (C) relative
to both plunger cylinders.
During this procedure take care not to dam-
age the wiper seal and oil seal grooves.
• Check the pistons and their cylinders for any signs of
scoring.
• Clean the parts thoroughly and flush with exclusively
alcohol.
• Always fit new wiper seals and oil seals. Refit the plungers,
oil seals (C) and wiper seals (B), lubricating with brake fluid.
After terminating the inspection, cleaning and replacement procedures, refit all the parts in reverse sequence with
respect to the sequence of disassembly.
NOTE After working on the braking system, always check that:
• The brake fluid lines are not damaged, crushed, or twisted.
• The discs and pads are not contaminated with oil or grease;
• All screws and unions are fully tightened.
• There are no leaks from any of the unions.
D I S A S S E M B LY
20 ± 20%
V
2
A
120 11/06
PASSWORD 250 i.e.
C
B
B
V
2
C