FRONT BRAKE
4-24
5. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-36.
EAS22290
REMOVING THE FRONT BRAKE CALIPER
IP
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Brake hose union bolt “1”
• Copper washers “2”
• Front brake hose “3”
IP
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
EAS22320
DISASSEMBLING THE FRONT BRAKE
CALIPER
1. Remove:
• Brake caliper pistons “1”
• Brake caliper piston dust seals “2”
• Brake caliper piston seals “3”
▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Blow compressed air into the brake hose joint
opening “a” to force out the pistons from the
brake caliper.
WARNING
EWA13550
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
b. Remove the brake caliper piston dust seals
and brake caliper piston seals.
▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS22380
CHECKING THE FRONT BRAKE CALIPER
1. Check:
• Brake caliper pistons “1”
Rust/scratches/wear → Replace the brake
caliper pistons.
• Brake caliper cylinders “2”
Scratches/wear → Replace the brake caliper
assembly.
• Brake caliper body “3”
Cracks/damage → Replace the brake caliper
assembly.
• Brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed air.
WARNING
EWA37P1010
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.
2
3
1
3
2
1
2
3
Recommended brake component replace-
ment schedule
Brake pads If necessary
Piston seals Every two years
Piston dust seals Every two years
Brake hose Every four years
Brake fluid
Every two years and
whenever the brake
is disassembled
a
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