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Rear Brake Caliper

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Disassembly

Remove the two Allen bolts that secure the rear caliper to the swingarm mounting bracket using a 6 mm Allen wrench.

Compress the brake holder bracket all the way in to remove the brake pads.

Remove the rear brake pads.

Remove the brake holder bracket and inspect for damage or wear to the slider pins and rubber boots- replace as needed.

Remove the inner brake caliper piston plug and inspect it for damage.

Remove the brake hose banjo bolt using a 12 mm wrench and discard the sealing washers.

Place a 1″ thick strip of wood 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 brake caliper dust seal and fluid seal using a pick.

Inspection

Clean all of the caliper components with aerosol brake cleaner and a lint free cloth. Inspect the caliper piston for corrosion or wear and check the O-rings for cuts or damage. Replace parts as necessary.

Reassembly

Before reassembling the brake caliper, coat the piston, piston bore and seals 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 of the piston bore. Install the caliper piston dust seal, also making sure it is properly in place.

Using a C-clamp, carefully compress the piston all the way in so the brake pads will clear the brake disc when installing the caliper. Make sure the closed end of the piston goes in first or you will never get the brake bled.

Place the caliper piston plug in the caliper piston.

Grease the brake caliper bracket slider pins with high temperature grease.

Slide the brake caliper bracket back into the caliper, making sure it moves smoothly.

Install the brake pads.

Slide the rear brake caliper onto the rear brake disc, making sure the disc fits in between the two brake pads.

Remount the brake caliper and torque the mounting bolts to specification.

rear brake caliper mounting bolt torque: 25 N-m or 18 ft-lb

Bleed the brakes. See the Rear Brake Bleeding topic for more information.

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