SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Warning: Brake fluid is very caustic and can damage paint, chrome and plastic. Wipe up any spills immediately.
Removal
Remove the front brake hose banjo bolt using a 12 mm wrench. Let the brake fluid drain into a container.
Remove the two front brake caliper Allen bolts using a 6 mm Allen wrench and slide the brake caliper off of the brake disc.
Disassembly
Remove the brake pads. See the Front Brake Pads topic for more information.
Place a 1″ thick strip of wood or a shop rag between the caliper piston and the inside surface of the brake caliper. Blow compressed air into the banjo bolt opening to remove the caliper piston. The caliper piston is a tight fit in the brake caliper and will pop out with a lot of force.
Caution: Do not place your fingers over the caliper piston while removing it as serious injury could result.
Remove the caliper piston.
NOTE: Never use pliers on the piston surface as damage could result.
Remove the brake pad holder by pulling it out of the brake caliper.
Remove the brake caliper piston dust seal and inspect it for tears or other damage. Replace as necessary.
Remove the brake piston fluid seal using a small pick. The brake piston fluid seal is a square section O-ring that is critical to brake performance. Inspect it for tears or other damage. Replace as necessary.
Assembly
Clean the brake caliper and the other components thoroughly using aerosol brake cleaner and a lint free cloth.
Before reassembling the brake caliper, coat the piston, piston bore and seal with a light layer of DOT 4 brake fluid from a tightly sealed container. Install the caliper piston fluid seal carefully, making sure it is completely fitted into its groove in the brake caliper. It should be almost flush with the inside surface of the piston bore.
Lightly grease the slider pins of the front caliper bracket slide it into the caliper.
Press the piston fully into the brake caliper, installing the closed end of the pistons first. The pistons will be a tight fit and may require the use of a c-clamp to get them fully seated.
Reinstallation
Slide the caliper over the brake disc, making sure the disc fits in between the two brake pads. Install the two Allen bolts and torque them to specification.
front brake caliper Allen bolt torque: 25 N-m or 18 ft-lb
Install the brake line banjo bolt using new sealing washers. Make sure to put one sealing washer on each side of the banjo fitting. Torque the banjo bolt to specification.
brake banjo bolt torque: 25 N-m or 18 ft-lb
Bleed the brakes. See the Front Brake Bleeding topic for more information.