Brake Caliper Front Removal and Overhaul [KC]

Special tools: 115 8147 torque socket, 981 4071 weatherstrip tool

Preparations [KC1]
- Remove wheel.

Draining brake fluid [KC2]

- Clean brake caliper carefully.
- Remove protective cap from bleed nipple and open nipple.





- Lock pedal in depressed position with a pedal jack.
- Collect emerging brake fluid.
- Undo brake hose (1/2 turn).

Removing brake caliper and brake pads [KC3]

- Undo brake hose (1/2 turn).





- Remove retaining spring (3) carefully to avoid deforming it.
- Remove protective caps (1) from the two locating pins (2).
- Remove locating pins, using 7 mm (0.276") hexagonal socket.

[KC4]

- Remove brake caliper carefully from mounting to avoid damaging brake hose.
- Remove brake pads.

Removing brake hose [KC5]

- Unscrew brake caliper from brake hose.
- Drain remaining brake fluid.

Dismantling brake caliper [KC6]

Warning: Take care to avoid getting fingers caught when piston is pushed out.





- Put a block of wood in front of piston. Push piston out carefully using compressed air.

[KC7]





- Remove dirt guard (3).
- Remove 0-ring (4). Use weatherstrip tool 981 4071 or similar so as not to damage edges of groove.
- Remove rubber bushings (7) and bleed nipple (5).

Cleaning and inspection [KC8]
- Clean components in T-spirit. Check for wear, damage, cracks and rust. Replace components if necessary.
- Always replace 0-ring and dirt guard during overhaul. Take particular care to clean ducts and grooves for 0-ring and dirt guard.
- If cylinder is badly marked, scratched etc., replace complete caliper.
- Remove minor rust deposits with fine sandpaper.

Assembling brake caliper [KC9]

- Blow ducts clean with compressed air.





- Coat cylinder lining, piston (2) and new 0-ring (4) with brake fluid.

- Install lubricated 0-ring (4) in groove in cylinder. Install dirt guard in end of piston (see illustration).

[KC10]





- Install dirt guard in groove inside cylinder and push piston in carefully.
- Check that dirt guard slots into its groove in the piston.
- Check that dirt guard is in position properly.
- Install bleed nipple (5), tighten to 9 Nm (7 ft.lb).

Finishing [KC11]





- Install rubber bushings in brake caliper.





- Screw brake caliper onto hose by hand.
- Hang brake caliper up on a steel wire on front spring to avoid damaging hose. Go to KA5. Service and Repair