Removing and installing front brake calliper
Warning: Do not separate the two halves of the brake calliper.
Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle or with the brake pads.
- Drain the brake system.
![](https://motoinstruction.ru/img/bmw/21/127427.jpg)
Caution: Avoid scratching the wheel rim; if necessary mask off the brake calliper.
- Remove screws (3) securing brake calliper.
- Carefully remove brake calliper, if necessary press it back and forth against the brake disc to force back the brake pads and pistons.
- Remove the brake pads.
See Group 00.
Caution: Do not operate the brake with the brake callipers removed from the motorcycle.
- Remove banjo bolt (1) for brake hose and remove brake hose.
- Installation is the reverse of the removal procedure: pay particular attention to the following.
Caution: Do not damage the brake pads when installing.
- Replace sealing rings of banjo bolt (1).
![](https://motoinstruction.ru/img/bmw/21/127428.jpg)
- If necessary, press the brake pads/pistons fully back with resetting tool, BMW No. 34 1 500.
- Fill and bleed the brake system.
See Group 00.
- Check/adjust ABS sensor gap.
- Sensor gap — 0.45...0.55 mm (0.018...0.022 in)
Tightening torques:
- Brake calliper to fork slider tube — 40 Nm
- Brake hose to brake calliper — 18 Nm
- Grubscrew in filler adapter — 10 Nm
- Bleed screw — 10 Nm
Removing and installing filler adapter
- Remove right-hand brake calliper.
- Remove the brake pads.
Caution: Make sure no traces of thread-locking compound penetrate the brake callipers.
![](https://motoinstruction.ru/img/bmw/21/127429.jpg)
- Clamp the brake calliper in a vise. Filler adapter (1) must point down to ensure that no traces of thread-locking compound can penetrate into the brake calliper when the filler adapter is slackened.
- Heat filler adapter (1) to approx. 80°C (176°F) and use an open-ended wrench to remove.
![](https://motoinstruction.ru/img/bmw/21/127430.jpg)
- Seal tapped bore in brake calliper with paper towel or similar (arrow).
- Clean threads; use a scribing tool or similar to loosen thread-locking compound residues and blow clear with a low-pressure jet of compressed air.
![](https://motoinstruction.ru/img/bmw/21/127431.jpg)
- Use piston resetting tool, BMW No. 34 1 500, to locate brake pistons.
- Apply compressed air to the connection bore (arrow) in the brake calliper to blow the interior clear of all traces of thread-locking compound.
- Remove all traces of brake fluid from threads.
- From this point on, installation is the reverse of the removal procedure.
Tightening torques:
- Filler adapter in brake calliper — 18 Nm (clean thread + new filler adapter or Loctite 243)
- Brake hose to brake calliper — 18 Nm
- Brake calliper to fork slider tube — 40 Nm
- Grubscrew in filler adapter — 10 Nm
- Bleed screw — 10 Nm
Removing and installing front brake pistons
- Remove the brake calliper.
- Use piston resetting tool, BMW No. 341500, to locate two opposing brake pistons.
- Insert a piece of cloth between the two brake pistons not located by the resetting tool.
Warning: Do not allow your fingers to become trapped between the pistons; risk of injury.
- Carefully press out one of the brake pistons, by applying a compressed air gun to the brake hose connection.
- Wrap a cloth round the empty bore for the brake piston to seal it as tightly as possible.
- Carefully press out the second brake piston, by applying the compressed air gun to the brake hose connection.
- Check brake pistons for hairline cracks, scores and damage.
- Remove the sealing rings from the bores for the brake pistons.
- Coat new sealing rings with brake fluid and install.
Caution: The brake pistons have a tendency to tilt in their bores during installation: always be careful to keep the pistons square to their bores when installing.
- Coat the brake pistons with brake fluid and carefully insert them into their bores.
- Remove and install the other two brake pistons in the same way.
- Installation is the reverse of the removal procedure: pay particular attention to the following.
- Before installing the brake calliper, force the pistons fully back with resetting tool, BMW No. 34 1 500.