4-45
FRONT BRAKE
8. Check:
• Brake lever operation
Soft or spongy feeling Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-16.
EAS30724
REMOVING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Brake hose union bolt
• Brake hose gasket
• Brake hose
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
EAS30172
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
brake calipers.
1. Remove:
• Brake caliper piston
• Brake caliper piston dust seal
• Brake caliper piston seal
a. Secure the right side brake caliper pistons
with a piece of wood “a”.
b. Blow compressed air into the brake hose
joint opening “b” to force out the left side
pistons from the brake caliper.
EWA17060
• Never try to pry out the brake caliper pis-
tons.
• Do not loosen the bolts “4”.
c. Remove the brake caliper piston dust seals
and brake caliper piston seals.
d. Repeat the previous steps to force out the
right side pistons from the brake caliper.
EAS30173
CHECKING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
1. Check:
• Brake caliper piston
Rust/scratches/wear Replace the brake
caliper pistons.
• Brake caliper cylinder
Scratches/wear Replace the brake caliper
assembly.
• Brake caliper body
Cracks/damage Replace the brake caliper
assembly.
• Brake fluid delivery passage
(brake caliper body)
Obstruction Blow out with compressed air.
WARNING
EWA13611
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.
Recommended brake component
replacement schedule
Brake pads If necessary
Piston seals Every two years
Piston dust seals Every two years
Brake hoses Every four years
Brake fluid Every two years and
whenever the brake is
disassembled
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