8.2.1. brake caliper overhaul

• Re-connect the cable to the brake pad wear indicator. Check that the cables cannot touch other parts of the front suspension when the wheels are moved from lock to lock.
• Operate the foot brake a few times to set the new pads against the brake disc. You will also find out if the brake systems requires bleeding. Pump the pedal with quick strokes. Air in the system is normally indicated by a rising pedal.
• Refit the wheels and lower the vehicle to the ground. Tighten the wheel nuts to 18 kgm (130 ft.lb.).
• Check and if necessary correct the brake fluid level in the reservoir.

Remember that new brake pads need a while to “bed” in, before the brakes obtain the full performance. Treat the brakes with care when you first drive off.

8.2.1. BRAKE CALIPER OVERHAUL

The brake caliper must be removed from the steering knuckle. Two bolts hold the caliper in position. As two brake hoses are fitted separate the connection between the hoses and the pipes, i.e. it is not possible to remove the brake caliper and then the brake hose. Brake pipes/hoses are connected with union nuts and spring plates. Close the ends of the brake pipes in suitable manner to prevent entry of dirt.

Fig. 8.5. — View of the fitted caliper. The bolts (2) must not be slackened or removed, as they keep the caliper halves together.

1. Brake hoses
2. Bolts
3. Bleeder screws

Fig. 8.5. shows the fitted caliper. The illustration shows the four bolts (2) which hold the caliper together. These are the bolts which must not be slackened or removed.

• Unscrew the two brake hoses (1) from the the caliper and remove the two bleeder screws (3).
• The pistons are blown out with air. Place a piece of hardwood into the caliper opening to allow the piston to “hit” the wood and not the metal. Remember that you have two pistons, it may be necessary to deal with one piston at the time. Keep the fingers away from the area of the piston opening when the caliper is dismantled. Fig. 8.6 shows the removal of a piston. You may be able to

Note the following general rules when overhauling brake calipers or for that matter any other hydraulic part:

• The work must be carried out on a clean workbench.
• All rubber cups and seals must be replaced if the part has been dismantled. even if rubber parts still look usable, replace them.
• Never refit a piston or caliper if corrosion or other blemishes can be found. Always replace the part in question. Only use alcohol, white spirit or brake fluid to clean parts. Even small amount of petrol can damage the rubber parts

with a lint-free cloth.