Caution: Do not leave the caliper hanging on the brake hose, this will cause the hose to deform and brake fluid to leak. Tie the caliper with wire.
Note:
- Before installing a new brake disc, remove the preservative coating from it using denatured alcohol or brake cleaner, dry the disc. Do not use gasoline, kerosene or other petroleum-based solvents for washing, which may leave an oily film.
- Before installing the brake disc, thoroughly clean the mounting areas of the disc and wheel hub. Rust or dirt getting under the mounting will cause axial runout of the brake disc.
- If the brake disc is to be removed using the two-bolt method, remove any burrs from the hub surface that may have been created by the bolts.
1. Check the fluid level in the master cylinder reservoir.
2. If the brake fluid level is in the middle between the maximum and minimum level marks, there is no need to remove the brake fluid from the reservoir before starting the check.
3. If the brake fluid level is above the middle, pump out the fluid to the middle between the marks.
4. Raise the vehicle and place safety stands under the frame.
5. Remove the front (or back) wheel. When removing the rear wheel disc, disconnect the parking brake cable.
6. If you plan to install the old brake disc, mark the relative position of the disc and wheel hub.
7. Insert the brake caliper pistons into the caliper:
- install a large clamp on the caliper body and on the outer brake pad;
- slowly move the clamp jaws together until the pistons are fully seated in the caliper;
- remove the clamp.
Caution: Remove the brake caliper bracket and caliper assembly.
8. Remove the two bolts securing the brake caliper bracket.
9. Hang the caliper and bracket on the wire from the frame.
10. If the brake disc is secured with additional nuts, unscrew these nuts.
11. Loosen the brake disc fixing screw.
1500 Series Front Brake |
2500 Series Front Brake |
1500 Series Rear Brake |
2500 Series Rear Brake |
12. Screw the wheel mounting nuts onto the hub studs.
13. Using a copper or plastic hammer, tap the disc between the studs and separate the disc from the hub.
14. Remove the wheel mounting nuts.
15. Remove the brake disc.
Except for the 2500 series rear brake
16. If the brake disc does not separate from the hub, perform the following operations:
- clean the threaded holes of the brake disc for the puller bolts;
- generously moisten the brake disc seat on the hub with penetrating lubricant (WD-40 or equivalent);
- screw M10x1.5 bolts into two holes of the disk;
- tighten the bolts evenly until the disc comes off the hub.
2500 Series Rear Brake Only
16. When removing the disc, simultaneously turn the disc with the traction force.
All brakes
17. Installation is carried out in the reverse order. After installation, check the runout of the brake disc, carry out the procedure for installing the brake pads.
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