Front
DISASSEMBLY1. NON-TURBO MODEL
1) Clean mud and foreign particles from the caliper body assembly and support.
CAUTION: Be careful not to allow foreign particles to enter inlet (at brake hose connector).
2) Gradually supply compressed air via caliper body brake hose to force piston out.
CAUTION:
^ Place a wooden block as shown in the figure to prevent damage to piston.
^ Do not apply excessively high-pressure.
3) Remove the piston boot.
4) Remove the piston seal from caliper body cylinder.
5) Remove the guide pin and boot from caliper body.
2. TURBO MODEL
1) Clean mud and foreign particles from the caliper body assembly and support.
CAUTION: Be careful not to allow foreign particles to enter inlet (at brake hose connector).
2) Using a standard screwdriver, remove the boot ring from piston.
3) Remove the boot from piston end.
4) Gradually supply compressed air via caliper body brake hose to force piston out.
CAUTION: Place a wooden block as shown in the figure to prevent damage to piston.
5) Remove the piston seal from caliper body cylinder.
6) Remove the lock pin boot and guide pin boot.
ASSEMBLY
1. NON-TURBO MODEL
1) Clean the caliper body interior using brake fluid.
2) Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body.
3) Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston.
4) Apply a coat of specified grease to the boot and fit in the groove on ends of cylinder and piston boot onto cylinder.
Grease: NIGLUBE RX-2 (Part No. 003606000)
5) Insert the piston into cylinder.
CAUTION: Do not force the piston into cylinder.
6) Position the boot in grooves on cylinder and piston.
7) Apply a coat of specified grease to the lock pin and guide pin outer surface, cylinder inner surface, and boot grooves.
Grease: NIGLUBE RX-2 (Part No. 003606000)
8) Install the lock and guide pin boot on support.
2. TURBO MODEL
1) Clean the caliper body interior using brake fluid.
2) Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body.
3) Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston.
4) Insert the piston into cylinder.
CAUTION: Do not force the piston into cylinder.
5) Apply a coat of specified grease to the boot and fit in the groove on ends of cylinder and piston.
Grease: NIGLUBE RX-2 (Part No. 003606000)
To facilitate installation, fit the boot starting with piston end.
6) Position the boot in grooves on cylinder and piston.
7) Install the boot ring. Be careful not to scratch the boot.
8) Apply a coat of specified grease to lock pin and guide pin, outer surface, cylinder inner surface, and boot grooves.
Grease: NIGLUBE RX-2 (Part No. 003606000)
9) Install the lock pin boot and guide pin boot on support.