Pic. 15–23. Front caliper HP-2: 1 - protective cap; 2 - bleed valve; 3 - caliper bracket body; 4 - sealing ring; 5 - piston; 6 - protective cover
Details of the front caliper HP-2 are shown in fig. 15–23.
Notes: Both parts of the caliper bracket body are bolted to the internal shaped recess and cannot be disassembled. If the protective covers of the guide pins are damaged, they must be replaced with new ones.
O-rings are removed using a mounting wedge, and installed by hand.
Clean the caliper of dust and dirt, but do not inhale the raised dust.
Secure the caliper in a vise. To remove the piston, apply low pressure air to the brake cylinder through the brake hose connection port. On the side of one piston, install a special tool for pressing the piston, which will hold the piston in place, and on the side of the second piston, install a block of wood.
Pic. 15–24. Using a wedge to remove the seal from the caliper cylinder groove
Remove the wooden block and carefully remove the piston. Carefully, so as not to damage the cylinder walls, remove the seal from the groove of the caliper cylinder with a mounting wedge or a flat screwdriver blade as a lever (pic. 15–24).
Check the condition of the cylinder and piston. Replace piston and cylinder if scratched, scored, worn, or pitted. Replace rubber seals regardless of condition.
Wash all parts in methanol or clean brake fluid and wipe dry.
Pic. 15–21. Installation location of the protective cover on the caliper piston
Apply a thin layer of grease G 052 150 A2 to the O-ring and piston (see fig. 15–21).
Install the dust cover on the piston so that the inner diameter of the cover fits into the piston groove.
Pic. 15–25. Using a special tool to install the working edge of the dust cover in the caliper
Install the piston against the caliper cylinder and, using a special tool, insert the working edge of the dust cover into the caliper until it locks into place (pic. 15–25).
Using a special tool or a hammer handle, press the piston into the caliper cylinder.
After installing the piston, blow out the cylinder with air and fill it with fresh brake fluid.
If it is necessary to replace the second piston, repeat the operations for removing and installing the caliper piston, when removing the piston, install a wooden block on the side of the second piston.
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