Front Caliper

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 wheel on the side you want to remove the brake. See the Wheels and Hubs topic for more information.

Drain the brake fluid. See the Brake Fluid topic for more information.

Loosen the brake hose banjo bolt with a 12 mm socket. Remove the banjo bolt and sealing washer.

There are two caliper mounting bolts for each front brake caliper.

Remove the two caliper mounting bolts with a 12 mm socket.

Remove the brake caliper and bracket.

Disassembly

Inspect the brake pad lining thickness. If either pad is out of specification, replace the brake pads as a set.

Pad Lining Thickness: 4.0 mm (0.16 in.)
Service Limit: 1 mm (0.04 in.)

Remove the brake pad pin clip with needle nose pliers.

Remove the brake pad pin.

Push the caliper bracket towards the piston side of the caliper. Swing out the inner brake pad.

Remove the inner brake pad.

Remove the outer brake pad.

Slide the caliper bracket out of the caliper.

Remove the caliper bracket boots.

Remove the brake pad spring.

Place a thick rag over caliper pistons and use compressed air to move the pistons out. Do not place your fingers over the caliper pistons while removing it as serious injury could result.

NOTE: Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else.

Remove the caliper pistons. Check the piston for any scratches, damage or excessive wear. Clean the piston with DOT 4 brake fluid.

Use a mechanics pick to remove the dust seal from the outer caliper bore and discard.

Use a mechanics pick to remove the piston seal from the inner caliper bore and discard.

Inspection

Check the brake caliper bore for any scratches, damage or excessive wear. Clean the brake caliper bore with DOT 4 brake fluid.

Assembly

Coat the caliper bore, the outside of the pistons, and the new seals with fresh DOT 4 brake fluid.

Install the piston fluid and dust seals into their grooves in the caliper. Install the piston into the caliper bore closed end first. Use an old brake pad to push the pistons all the way into the caliper.

Install the brake pad spring.

Install the rubber caliper bracket pin boots into the caliper.

Lightly coat the caliper bracket pins with grease. Install the caliper bracket to the caliper and push it all the way in.

Install the outer brake pad.

Hook the inner brake pad onto the bracket and rotate it into the caliper.

Insert the brake pad pin.

Insert the pad pin clip into the pad pin so that it sits outside of the brake pads.

Installation

Install the brake caliper over the disc brake.

Install the two brake caliper mounting bolts and tighten them to specification with a 12 mm socket.

Caliper Mounting Bolts: 25 N-m, 2.5 kgf-m, 18 ft-lb

Connect the brake hose to the caliper. Install new sealing washers and tighten the brake hose banjo bolt to specification with a 12 mm socket.

Brake Hose Banjo Bolt
2002 – 2003: 25 N-m, 2.5 kgf-m, 18 ft-lb
2005 – 2011, 700cc: 34 N-m, 3.5 kgf-m, 25 ft-lb

Install the front wheels. See the Wheels and Hubs topic for more information.

Fill the master cylinder reservoir with brake fluid and bleed the brakes. See the Brake Fluid topic for more information.

Check that the brakes work properly before riding.