2. Carefully inspect all components. Replace any parts that
appear damaged or worn.
a. Check pistons for pitting, scratches or corrosion on
face and also on ground surfaces.
b. Inspect phenolic insulators for damage.
c. Inspect caliper piston bore. Do not hone bore. If bore
should show pitting or corrosion, replace caliper.
d. Inspect pad pin for grooving and wear. Measure the
pad pin diameter in an unworn area, and then in the
area of any grooving or wear. If wear is more than
0.015 in. (0.38 mm), replace both pins.
e. See Figure 2-76. Inspect dust boot (13) for cracks
and damage. Inspect bushing (14) for free movement.
Inspect bushing (2) for free movement or damage.
f. Always replace square seals after disassembly.
3. If decal on outside housing is removed, scrape remaining
adhesive from surface with a razor blade.
4. Inspect brake pads and brake disc. See 1.16 BRAKE
PADS AND DISCS.
ASSEMBLY
NOTE
Do not use D.O.T. 4 brake fluid for lubrication. Use of D.O.T.
4 brake fluid will result in increased lever travel.
1. Lubricate the following parts prior to assembly using a
light coat of G.E. VERSILUBE® #G322 L SILICONE
GREASE (marked "Piston Lube") from the service parts
kit. All other surfaces must be dry for assembly.
a. Lubricate nose radius and outside diameter of piston.
Apply lube to inside of caliper piston bores.
b. Apply lube to inside diameter of square seals.
Avoid leakage. Prevent damage to piston or piston bore.
Use non-metallic tools when servicing components.
(00529d)
2. See Figure 2-78. Install two new square seals (2) into
each piston bore. Use a wooden toothpick (1) to aid
installation if needed.
3. Install anti-rattle spring (3). Ensure it is oriented correctly.
4. Carefully insert pistons, by hand, into bores of caliper
housing. Press pistons squarely into place until they
bottom in the bores. If installation shows resistance,
remove piston and check that seals are properly installed.
5. See Figure 2-76. Install bleeder valve (4) (with o-ring) in
caliper housing, if removed, and tighten to 80-100 in-
lbs (9.0-11.3 Nm).
NOTE
Ensure phenolic insulators (8) are in place before installing
brake pads.
6. Insert brake pads into caliper with friction material facing
opening for brake disc.
7. Install pad pin (3) and tighten to 80-120 in-lbs (9.0-13.6
Nm).
NOTE
If pad pins do not fit, check the following:
• You are using a set of pads, not two identical pads.
• Anti-rattle spring orientation matches Figure 2-76.
INSTALLATION
1. Install rear axle and caliper mount if removed. Ensure
notch in mount engages tab on rear fork. See 2.4 REAR
WHEEL.
2. See Figure 2-76. Ensure torque clip (9) is in place in cal-
iper mount.
3. See Figure 2-75. Install caliper with pads on caliper mount.
Tighten slider pin (3) and mounting bolt (4) (metric) to 10-
14 ft-lbs (13.6-18.9 Nm). Ensure tabs on brake pads
engage slot (5) in caliper mount.
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and caliper bore are clean and undamaged before
assembly. (00321a)
4. Lubricate new steel/rubber washers with D.O.T. 4 BRAKE
FLUID. Connect the brake line to caliper using two new
washers (2) and banjo bolt (1). Tighten to 21-25 ft-
lbs (28.5-33.9 Nm).
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)
5. Remove cover from rear brake master cylinder. Fill master
cylinder with D.O.T. 4 BRAKE FLUID.Verify that fluid level
is 1/8 in. (3.2 mm) below top of reservoir with master cyl-
inder in a level position.
After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)
6. Bleed brake system. See 1.15 BLEEDING BRAKES.
After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)
2-48 2008 Dyna Service: Chassis
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