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Brake Calliper – Rear Wheel Brake, Remove
and Install
Note: The brake pads
must be removed to remove the brake calliper of the rear wheel
brake.
 Remove
| 1. |
Release parking brake cable
| • |
Release parking brake lever
|
| • |
Detach parking brake bellows
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| • |
Release parking brake cable by unscrewing adjusting nut
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| 2. |
Top up brake fluid reservoir to "MAX" marking and seal with
MKM-558-10 .
|
| 3. |
Detach appropriate rear wheel
| • |
Unscrew 4 x screws
Note: Mark position in
relation to centre of wheel
|
|
| 4. |
Release brake calliper
| • |
Unhitch parking brake cable
| – |
Push down brake calliper actuation lever with screwdriver and
detach parking brake cable.
|
| – |
Pull off locking plate (3)
|
| – |
Draw parking brake cable out of mounting on brake calliper
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| • |
Unscrew 1 x screw (1)
| – |
Hold against hexagon of guide pin (2).
|
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| • |
Fold brake calliper upwards
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| 5. |
Unscrew brake piston
Note: Brake fluid rises
in the reservoir, if necessary siphon with siphon bottle.
| • |
Turn brake piston back with KM-6007-A
(1) and KM-6007-30 (2)
Note: The collar of
KM-6007-30 must point in the direction of
the hand wheel or hexagonal section of KM-6007-A .
| – |
Turn piston back to stop.
|
| – |
Screw piston outwards again until the next cut-out in the brake
piston is aligned with the opening on the brake calliper
(arrows)
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| 6. |
Remove the brake calliper from the brake support
Note: The brake
calliper must be completely removed from the brake carrier before
mounting the brake pads.
| • |
Unscrew bolt (1)
| – |
Hold against hexagon of guide pin (2).
|
|
| • |
Detach the brake calliper from the brake carrier.
|
| • |
Suspend brake calliper from the rear spring with a suitable
wire.
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| 7. |
Remove brake pads and guide plates
|
| 8. |
Detach brake hose (1) from brake calliper
Note: Collect escaping
brake fluid and seal aperture
|
| 9. |
Detach bolts (3) for brake carrier (2) from brake backing plate
and remove brake carrier.
|
|
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Install
| 10. |
If brake calliper leaks, protective cap on brake calliper is
damaged or brake carrier sealing sleeve is damaged: Replace brake
calliper / brake carrier
|
| 11. |
Attach brake calliper to brake carrier plate 100 Nm
Note: Clean thread and
insert bolts with locking compound.
|
| 12. |
Install brake pads with new adhesive film 
|
| 13. |
Attach parking brake cable to bracket with new retaining clamp
(3)
| • |
Press actuating lever (2) downwards with screwdriver
|
| • |
Hitch up parking brake cable
|
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| 14. |
Attach brake hose (1) to brake calliper with new seal rings
40 Nm
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| 15. |
Fit rear wheel 110 Nm
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| 16. |
Bleed brake system and check for leaks
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| 17. |
Actuate brake pedal repeatedly
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| 18. |
Top up brake fluid to "MAX" mark
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| 19. |
Parking Brake, Adjust
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