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BRAKES
e. Slowly
apply
the
brake
lever to push the pis-
ton
part
way out of
caliper
assembly
for case
of
remova
l
during
caliper
service.
d.
Loosen and
remove the brake hose
from
the
rearof
the
caliper.
e.
Place
the
loose
end
of the
brake hose
in
a
reclosable plastic bag to prevent the
entry
of
debris
and to
prevent
any
residual
brake fluid
from dripping
out,
2. Remove the
caliper
mounting bolts
and
remove
the
output
shaft
caliper
from
the transmission.
3.
If
necessary, disassemble, insp ect
and
assemb
le
the
output
shaft
caliper
as desc
ribed in
this
c
hapter.
4.
Install
by reversing these
removal
steps while
noting
the
following:
a.
Carefully
install
the
caliper
asse
mbly onto the
disc,
being
careful
not to damage the leading
edge
of
the brake
pads.
b.
Install
the
caliper
mounting
bolts
and tighten
to
the
torque
specifications
listed in Table
2.
c.
Bleed
the
brake as
described
under
Bleeding
the
System
in
this
chapter.
fl,4RNI NG
Make
sure the brakes
operate prop-
erly
before
riding the
vehicle.
Disassembly
Refer to
Figure
28.
l
.
Remove the brake pads as
described
in
this
chap-
ter.
2. Remove the
caliper
as
described
in
this
chapter.
3. Make
an alignment
mark
on
the ca
liper
body
and
the stationary ramp.
To
ensure
correct
alignment
during assembly.
395
NOTE
Figure
32
sho
ws the caliper bra
ke
arm removed
to
better illustrate the
st
ep. It is
no!
Il
ecessmy
to
remo\'e the
caliper
brake arm
.
4. Remove
the
two screws (F
igu
re 32
), then
re-
move
the
stationary ramp
assembly.
Remove
the
gasket
from
the ca
liper
body
and
discard
it.
5.
Remove
the brake
app ly
pin and spri
ng
(F
igure
33).
NO TE
lf
the
piston
~vas
partially
fo
rced out
of
the
caliper
body
during
removal,
Steps
6-8
may not
he
necessary.
If
the
piston
or
caliper
bore
are corroded
or
vel:.\'
dirty : a small
amount
of
com-
pressed
air may be neces sary to
com-
pletely
remove
the
piston
fro
m
the
body
bore.
6.
Place
a
piece
of
soft
wood or folded shop
cloth
over
the
end
of the
piston
and
the caliper
body.
WA
RNING
III the
next
st
ep.
the
piston
mG
..
\ -'
shoot
out
of
the caliper body.
Keep all
Jill
-
gers
(Jut of
the
a'ay.
H~ar
gl
oves
and
apply air
pressure
g
radually Do
1101
use high-p ressure
oil' or
p
lace the air
hose nozzle directly
against the brake
hose
jilting
inlet
in the caliper
body.
lIold
the
air
nozzle
awayfrom
the ill-
let
,
allowing
some
ofthe air
fa
escap
e.
7.
Apply the
air
pressure
in short spurts to
the brake
hose
inlet
fitting
and force the
piston
out
of the
cali-
per bore.
CA UTI ON
III
the
fo llowing
step, do not
lise
a
sharp tool to
remove
the
dust and
pis-
ton seals
fro
m
the
caliper
cylinders.
Do
not
damage the cy linder
s
urface.
8.
Remove the dust
seal
a
nd
piston seal (I'igu re34
)
from
the inside
of
the cy
linder.
9.
Remove
the O-ring
seals
(Figure 35
) from
the
brake
apply
pin
bore
in
the
caliper
body.
10.
Unscrew and remove
the bleed
screw from
the
backside of
the
caliper.
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