Removal
Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Caution: To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork.
1. Disconnect the rear brake hose at the caliper and place the free end of the hose in a suitable container to collect the brake fluid.
2. Remove the caliper mounting bolts.
3. Remove the brake caliper assembly.
1. Caliper mounting bolts
Disassembly
1. Remove the plug protecting the pad retaining pin.
2. Remove the pad retaining pin.
3. Remove the brake pads and anti-rattle spring.
Warning: To prevent injury, never -place fingers or hands inside the caliper opening when removing the piston. Always wear eye, hand and face protection when using compressed air. Eye, face and skin damage will result from direct contact with compressed air.
4. Cover the caliper opening with a clean, heavy cloth and, using either compressed air or by reconnecting the master cylinder and pumping the brake lever, remove the piston.
Inspection
1. Check the piston and caliper bore for corrosion, scoring and damage. Renew as necessary.
Warning: Always renew caliper seals and pistons after removal from the caliper. An effective hydraulic seal can only be made if new components are used. A dangerous riding condition leading to an accident could result if this warning is ignored.
2. Inspect the brake pads for damage and wear beyond the service limit. Renew as necessary.
Assembly
Warning: Never use mineral based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible. Mineral based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders. Damage caused by contact with mineral based grease may reduce braking efficiency resulting in an accident.
Warning: Ensure that the caliper bores do not become scratched during removal and assembly. A dangerous riding condition leading to an accident could result if this warning is ignored.
Warning: Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid. Never use solvents, petrol (gasoline), engine oil, or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders. A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored.
1. Fit new fluid seals to the caliper. Apply brake fluid to the outside of the caliper piston and fluid seal.
1. Piston; 2. Seals
Warning: Ensure that the piston does not tip during assembly as this could damage the caliper. A dangerous riding condition leading to an accident could result if this warning is ignored.
2. Carefully push the piston into the caliper by hand.
3. Install the anti-rattle spring into the caliper.
4. Position the brake pads in the caliper.
Warning: Do not apply more than a minimum coating of grease to the pad retaining pins. Excess grease may contaminate the brake pads, hydraulic seals and discs causing reduced braking efficiency and an accident.
5. Lubricate the pad retaining pin using a minimum amount of proprietary high temperature 'Copaslip' type grease.
6. Fit and tighten the pad retaining pin to 18 Nm.
7. Fit the retaining plug and tighten to 3 Nm.
8. Apply a thin smear of silicone based brake grease to the outside of the sleeve and the sliding section of the bolt as shown below. Do not apply grease to the threads of the bolt.
1. Bolt; 2. Sleeve
Installation
1. Position the caliper over the disc ensuring the pads are correctly aligned on both sides of the disc.
2. Fit the caliper retaining bolts and tighten to 22 Nm (M8 bolt) and 27 Nm (M12 bolt).
3. Connect the brake hose to the caliper incorporating new washers on each side of the banjo bolt
4. Tighten the banjo bolt to 25 Nm.
Warning: Use only DOT 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident. Observe the brake fluid handling warnings given earlier in this section of the manual.
5. Fill the master cylinder with new, DOT 4 brake fluid from a sealed container.
6. Bleed the rear brake (see page 14-23).
7. Check for correct brake operation. Rectify as necessary.
Warning: lt is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you ride the motorcycle again. Failure to take remedial action may result in reduced braking efficiency leading to loss of motorcycle control and an accident.