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Caliper front brake
Withdrawal | - Remove the front wheel.
- Remove the banjo bolt and disconnect the brake hose from the caliper.
 | To eliminate leaking brake fluid, close the hole in the brake hose suitable stopper. |
- Remove the caliper mounting bolts.
- Remove the caliper and brake pads.
- Remove the screws of the caliper to the steering knuckle.
 | - Remove the fixing member support.
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Check | - Check the support for wear, damage, cracks and rust.
- Check piston for rust, damage, cracking and wear of the outer surface.
- Check the plug and the guide pin for damage and rust.
- Check the spring and covers for damage.
- Check the fastening element for wear, damage, cracks and rust.
 | - Do not use sandpaper to clean the surface of the piston.
- All rubber parts must be replaced with new ones.
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 | - Measure the thickness of the brake disc. Dial indicator, measure the brake disc run-out at a small distance from the outer edge.
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Brake Disc Thickness: Par: 24 mm
The minimum allowable: 22.4 mm
Maximum permissible palpation: 0,08 mm
Maximum allowable difference in the thickness of the brake disc: 0.01 mm | - Micrometer, measure disc thickness at eight positions, approximately every 45 ?� at a distance of 10 mm from the outer edge of the disc.
- Indicator of hour type check up palpation of a brake disk. The indicator of hour type fix in any convenient place and, turning the brake disk, define its palpation at a distance of 5 mm from the outer edge.
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- If necessary, replace the brake disc.
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Dismantling | - Remove the dust cover of the piston.
 | - Compressed air squeeze out the piston from the cylinder support.
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| - When extrusion piston compressed air do not place your fingers in front of the piston.
- Be careful, as the channel of the compressed air is blown out together with the piston brake fluid.
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 | - Blade screwdriver to remove the O-ring from the piston.
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Assembly | - Clean all parts except the brake pads, with isopropyl alcohol.
 | - Apply special grease on the O-ring piston and place it in the groove of the piston.
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 | - Assemble the piston and the piston covers in the following order:
- Apply special grease to the cylinder wall support, the outer surface of the piston and the piston case;
- Set the cover of the piston as shown in the figure;
- Insert the cover of the piston into the inner groove of the caliper and push the piston in the caliper.
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 | - Assemble the moving parts in the following order:
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 | - Apply special grease to the outer surface of the sleeve, and the guide pin in the hole for the hub and install protective covers;
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 | - Insert covers into the grooves of a support.
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- Install the brake pads.
| Never apply grease to the brake disc and brake pads. |
- Replace and tighten to a torque of banjo bolt brake hose.
Tightening torques: Guide pin: 35-45 N ??? m
Guide pin bolts: 22-33 N ??? m
Bolt fastening element caliper: 65-75 N ??? m
Banjo bolt brake hose: 25-30 N ??? m
| - Before installing, make sure that the surface of the bolts and the guide pin is not damaged.
- Remove air from a hydraulic drive of the brake system. Repeatedly press the brake pedal and check for leakage of brake fluid.
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Setting Installation is performed in reverse order of removal. | - Install the brake pads and caliper. Never apply grease to the brake disc and brake pads.
- Replace and tighten to torque caliper mounting bolts.
 | - Replace and tighten to a torque of banjo bolt brake hose.
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- Fill the brake fluid reservoir. Remove air from a hydraulic drive of the brake system. Repeatedly press the brake pedal and check for leakage of brake fluid.
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