8.2. Front Disc Brakes (page 2 of 2)

Fig. 8.4. — After removal of the upper bolt (see Fig. 8.3) swing the caliper downwards to expose the brake pads.

1. Inner brake pad
2. Guide bolt
3. Cylinder dust seal
4. Outer brake pad
5. Guide bolt rubber seal

8.2 and close the pliers. The pistons will be forced back into the cylinder. You may, of course, employ a different method to reset the pistons.

• Refer to Figs. 8.3 and 8.4 to remove a brake caliper. Remove the bolt (1) in Fig. 8.3 with a ring spanner, counterholding the guide bolt (2) in Fig. 8.4 with a second ring spanner or open-ended spanner. The guide bolt must not rotate.
• Swing the caliper downwards into the position shown in Fig. 8.4. The brake pad (1) at the inside and the pad (4) at the outside can now be removed from the caliper.

Clean the inside of the brake caliper opening with a stiff brush to remove brake dust. The pistons must now be pressed into their bores, if they appear to be protruding more than the caliper bore. Use a hammer handle, but have a helper observing the fluid level in the reservoir, as the fluid will rise, as the pistons are pushed in. If necessary remove some fluid out of the reservoir or open the bleed screw whilst the first piston is pushed in. Careful handling will not allow air into the system — otherwise the brake system must be bled of air. If the sealing rubbers (5) in Fig. 8.4 are in bad condition, unscrew the guide bolt (2). Clean the bolt and refit it with the new rubber part. The guide bolt is fitted with rubber grease. The installation of the brake pads follows the description below:

• Insert the inner brake pad (1) and the outer pad (4) in Fig. 8.4. The inner pad has the cable for the pad wear indication and must be routed through the opening "a" in Fig. 8.3.
• Check once more that the pads are fitted correctly and swing the caliper upwards, until the bolt at the top can be fitted. New bolts are normally included in the brake pad repair kit. If none are supplied, coat the threads with "Loctite".
• Hold the guide bolts (2) in Fig. 8.4 with an open-ended spanner and tighten the bolt (1) in Fig. 8.3 to 3.4 kgm (25 ft.lb).