Front

FRONT BRAKE





COMPONENTS

OVERHAUL

HINT:
- Use the same procedures for the RH side and LH side.
- The procedures listed below are for the LH side.

1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.

3. DISCONNECT FRONT FLEXIBLE HOSE
a. Remove the union bolt and the gasket(s) from the disc brake cylinder assembly, then disconnect the flexible hose.





4. REMOVE DISC BRAKE CYLINDER ASSEMBLY LH
a. Hold the cylinder slide pin (No.1) and cylinder side pin (No.2), and remove the 2 bolts.
b. Remove the disc brake cylinder assembly.
5. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Remove the 2 disc brake pads with anti-squeal shims from the cylinder mounting LH.
6. REMOVE ANTI SQUEAL SHIM KIT FRONT
a. Remove the 2 anti-squeal shims from the pads.
b. Using a screwdriver, remove the 2 pad wear indicator plates from the pads.
7. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
a. Remove the pad support plate (No.1) and pad support plate (No.2) from the cylinder mounting LH.





8. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Remove the cylinder slide pin (No.1) and cylinder slide pin (No.2) from the cylinder mounting LH.





9. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH
a. Using a screwdriver, remove the cylinder slide bush from the cylinder slide pin (No.2).

NOTICE: Do not damage the cylinder slide pin (No.2).

HINT: Tape the screwdriver tip before use.





10. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Remove the 2 bolts and cylinder mounting LH.





11. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
a. Hold the cylinder mounting LH in a vise between aluminum plates.
b. Using a screwdriver and hammer, remove the 2 bush dust boots from the cylinder mounting LH.

NOTICE: Do not damage the cylinder mounting LH.





12. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the set ring and cylinder boot.

NOTICE: Do not damage the piston groove or cylinder groove.

HINT: Tape the screwdriver tip before use.





13. REMOVE FRONT DISC BRAKE PISTON
a. Place a shop rag or a piece of cloth between the disc brake piston and the disc brake cylinder assembly.
b. Use compressed air to remove the disc brake piston from the disc brake cylinder assembly.

CAUTION: Do not place your fingers in front of the piston when using compressed air.

NOTICE: Do not spatter the brake fluid.





14. REMOVE PISTON SEAL
a. Using a screwdriver, remove the piston seal from the disc brake cylinder assembly.

NOTICE: Do not damage the inner cylinder or cylinder groove.

HINT: Tape the screwdriver tip before use.

15. REMOVE FRONT DISC BRAKE BLEEDER PLUG
16. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
17. INSPECT BRAKE CYLINDER AND PISTON
a. Check the brake cylinder bore and disc brake piston for rust or scoring. If necessary, replace the disc brake cylinder assembly and disc brake piston.





18. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 12.0 mm (0.472 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the pad lining thickness is equal to or less than the minimum thickness, replace the brake pad.
19. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
a. Inspect the pad support plate (No.1) and pad support plate (No.2).

HINT: Make sure that both plates have sufficient rebound and have no deformation, cracks or wear, and that all rust and dirt is cleaned off.

If necessary, replace the brake pad support plates.





20. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 28.0 mm (1.102 inch)
Minimum thickness: 26.0 mm (1.024 inch)
If the disc thickness is less than the minimum, replace the disc.





21. REMOVE FRONT DISC
a. Put matchmarks on the front disc and the axle hub.
b. Remove the front disc.
22. INSTALL FRONT DISC
a. Aligning the matchmarks, install the front disc.

HINT: When replacing the disc with a new one, select the installation position where the front disc has the minimum runout.





23. INSPECT DISC RUNOUT
a. Check the bearing play in the axial direction and check for axle hub runout.
b. Temporarily fasten the front disc together with the hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
c. Using a dial indicator, measure the disc runout 10 mm (0.39 inch) from the outer edge of the front disc.
Maximum disc runout: 0.05 mm (0.0020 inch)
If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maximum even when the installation positions are changed, grind the disc. If the disc thickness is less than the minimum, replace the front disc.
24. INSTALL FRONT DISC BRAKE BLEEDER PLUG
25. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
26. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to a new piston seal.
b. Install the piston seal to the disc brake cylinder assembly.





27. INSTALL FRONT DISC BRAKE PISTON
a. Apply lithium soap base glycol grease to the disc brake piston and new cylinder boot.
b. Install the cylinder boot to the disc brake piston.
c. Install the disc brake piston to the disc brake cylinder assembly.

NOTICE: Do not install the piston forcibly in the disc brake cylinder assembly.





28. INSTALL CYLINDER BOOT
a. Install the cylinder boot to the disc brake cylinder assembly.

NOTICE: Install the cylinder boot securely into the grooves of the cylinder and piston.

b. Using a screwdriver, install the set ring.

NOTICE:
- Install the set ring securely into the grooves of the cylinder boot.
- Do not damage the cylinder boot.

HINT: Tape the screwdriver tip before use.





29. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
a. Secure the cylinder mounting LH in a vise.
b. Apply lithium soap base glycol grease to the sealing surface of 2 new bush dust boots.
c. Using a socket wrench (19 mm) and hammer, install the 2 bush dust boots to the cylinder mounting LH.
30. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH
a. Apply lithium soap base glycol grease to a new cylinder slide bush.
b. Install the cylinder slide bush to the cylinder slide pin (No.2).





31. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Apply lithium soap base glycol grease to the sliding part and the sealing surface of the cylinder slide pin (No.1) and cylinder slide pin (No.2).
b. Install the cylinder slide pin (No.1) and cylinder slide pin (No.2) to the cylinder mounting LH.
c. Install the cylinder slide pin (No.2) to the cylinder mounting LH.





32. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Install the cylinder mounting with the 2 bolts.
Torque: 107 Nm (1,090 kgf-cm, 79 ft. lbs.)
33. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
a. Install the pad support plate (No.1) and pad support plate (No.2) to the cylinder mounting LH.





34. INSTALL ANTI SQUEAL SHIM KIT FRONT
a. Apply disc brake grease to the anti-squeal shims and install them to each pad.

NOTICE:
- When replacing worn pads, replace the anti-squeal shims together with the pads.
- Install the shims in the correct positions and directions.

b. Install the 2 pad wear indicator plates to the pads.
35. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Install the disc brake pads with anti-squeal shims to the cylinder mounting LH.

NOTICE:
- There should be no oil or grease on the friction surface of the pads and the disc.
- Install the brake loads with indicator elates facing upward.





36. INSTALL DISC BRAKE CYLINDER ASSEMBLY LH
a. Install the disc brake cylinder assembly with the 2 bolts.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
37. INSTALL FRONT FLEXIBLE HOSE
a. Connect the flexible hose with the union bolt and new gasket(s).
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)

NOTICE: Install the flexible hose lock securely in the lock hole in the disc brake cylinder assembly.

38. FILL RESERVOIR WITH BRAKE FLUID
39. BLEED BRAKE LINE
40. CHECK FLUID LEVEL IN RESERVOIR
41. CHECK BRAKE FLUID LEAKAGE
42. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)