Reconditioning brake caliper guide

AR42.10-D-0400A

Reconditioning brake caliper guide

15.1.10



Remove

Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A



Notes on repairs to brake system

All models

AH42.00-P-0003-01A



Brake fluid notes

All models

AH42.50-P-0001-01A

1

Unscrew cap from brake fluid reservoir

2

Remove front wheels

AR40.10-D-1100A

3

Push back top part of brake caliper with assembly lever.

 If the brake fluid level in the reservoir is too high, suction off a little brake fluid.

4

Detach wear indicator cable (7) from plug.

5

Remove dust caps (2).

6

Unscrew top part of brake caliper (4).

7

Pull guide sleeve (5) and bellows (6) out of top part of brake caliper (4).

8

Check brake pads (8)

 Brake lining wear limit

*BE42.10-N-1001-10A

9

Clean brake parts and check for wear and damage

AR42.10-D-1600-11A



*124589051900



*000589266800

 Brake disk wear limit.

If the brake disk measurement is below the wear limit: 

*BE42.10-N-1001-08B

Replace brake disks

AR42.10-D-0230D



Install

10

Insert new bellows (6) into seat of top part of brake caliper (4).

 Coat inside of bellows with grease provided.

11

Install new guide sleeves (5) in top part of brake caliper (6).

 Coat guide sleeves and guide bores with grease provided. Ensure that bellows are installed correctly in the groove of the guide sleeves.

12

Mount top part of brake caliper (5).

 Use M8 tapping tool to remove residue of self-locking coating from the brake carrier (1). Replace bolts (3).

When installing, ensure that the brake hose is not twisted.



*BA42.10-N-1004-10A

13

Mount dust caps (2).

14

Push on wear indicator cable (7).

15

Fit front wheels

 Ensure that all brake parts have sufficient clearance.

AR40.10-D-1100A

16

Operate brake pedal several times until brake pressure has built up.

17

Check fluid level in reservoir and correct if necessary



AP42.50-D-4210A

18

Check brake system for leaks

Number

Designation

Model 905

BE42.10-N-1001-10A

Brake lining wear limit

mm

3

Number

Designation

Model
905

BE42.10-N-1001-08B

Brake disk

Thickness when new

mm

26

Wear limit

mm

23

Lateral runout

mm

0.04

Flatness deviation

mm

0.02

Repair limit dimension

mm

-

Number

Designation

Model 905

BA42.10-N-1004-10A

Guide pin/catch bolt, top section of brake caliper to brake caliper support

M8

Nm

30

M10/10.9

Nm

-