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thefox
09-26-2008, 06:42 PM
I am rebuilding my rear caliper but I found a discrepancy between the parts diagram and the repair manual. I ordered 2 of the rubber boots that go on the mounting shaft but the manual only shows one. If it does have 2 (and I think it should) I can’t get them both on. So if it uses both boots is there a trick to putting them on?

Repair manual picture
http://i259.photobucket.com/albums/hh293/thefoxman45/rearcaliper.jpg

parts diagram... rubber boot that I am talking about is part #24
http://i259.photobucket.com/albums/hh293/thefoxman45/frombrake.jpg
DeePa
09-26-2008, 07:15 PM
there are supposed to be 2, but theyre a *Edited**Edited**Edited**Edited**Edited*. gotta keep on fighting with it. gotta get one side on, get the slide in there, then do the other side.
blue27
09-26-2008, 07:18 PM
yes there are 2 and they are a pain. I will see if I can help....
make sure the grooves in the caliper for the boots to fit in are clean(I use a dremel with a smalll wire wheel). Install the inner one and then slide the shaft through (a little lube helps). push the shaft far enough to expose the groove for the outer boot. Install boot and slide the shaft back in postion. It will take a couple of tries to get the hang of it. Maybe somone else has an easier way, but thats the best I got.

Good Luck!!!
thefox
09-26-2008, 07:57 PM
ok, I will give it a try again. The shaft and boots are new so I would think it would be easier but of course not. Then again I did end up drilling out the old (stripped) shaft...
thefox
09-26-2008, 08:07 PM
Success! I put the boot in opposite the brake pads then greased up the shaft and slid it through passed the point it should sit. The worked the other boot over the shaft and worked it in. Now to see if my rebuild works…
blue27
09-26-2008, 08:39 PM
Glad to hear that!!!
Erics350x
09-27-2008, 01:00 AM
I gave up after tearing two of those little $#%^ things up!
thefox
09-28-2008, 09:39 AM
I gave up after tearing two of those little $#%^ things up!

I tell ya grease is the key. I was able to get in installed in only a few minutes, both times (put in backwards the first time :rolleyes: ). It is a part that should be greased anyways.