Disassembly
1. Remove bracket assembly.
2. Remove the caliper guide pin that connects the caliper piston housing to the bezel.
3. Remove the bypass valve fitting and bypass valve.
4. Remove the pins and rubber covers.
5. Remove the front brake pads.
Warning: do not try to catch the piston with your fingers when removing the compressed air piston. The piston can suddenly pop out of its cavity and seriously injure your hand or finger.
Caution: When removing the piston, insert a piece of hardwood into the caliper body.
4. With compressed air «blow out» piston from the body.
5. Remove the outer seal.
6. Remove the inner o-ring from the caliper piston cavity.
Assembly
1. Wipe all parts with denatured alcohol or brake fluid. Dry them with clean compressed air and blow out all passages in the body and bypass valve.
2. Inspect piston and caliper for gouges, nicks and corrosion. If any of these components are found, then replace the specified nodes.
3. Inspect the clevis bypass valve.
Caution: Do not remove anything from the piston or cylinder bore.
4. Lubricate the new inner piston o-ring.
5. Install the inner piston o-ring into the groove in the caliper body. Check that the O-ring is not bent.
6. Insert the outer protective piston seal into the groove.
7. Lubricate the piston with brake fluid.
8. Push the piston inwards until it is properly seated in its seat.
9. Coat the mounting pins with grease and place protective covers on them.
10. Tighten the cylinder bleed valve to 6 Nm.
11. Install the brake shoes and springs.
Attention: make sure the shoe springs are installed correctly.
12. Attach the frame to the bracket with the bolts of the guide mounting pins.
Puff
Tighten the bolts securing the frame to the bracket body to 27 Nm.
13. Install the caliper.
14. Remove air from the system.
15. Press the pedal several times until the pedal becomes hard.