Front

Front Brakes:

REMOVAL

1. Remove front wheel.





2. Disconnect flexible hose.
(a) Remove the union bolt and 2 gaskets from the Caliper, then disconnect the flexible hose from the Caliper.
Torque: 29 Nm (300 kg.cm,21 ft. lbs.)

NOTE: Install the flexible hose lock securely in the lock hole in the Caliper.

(b) Use a container to catch the brake fluid as it drains out.
3. Remove Caliper.
(a) Remove the 2 installation bolts.
Torque: 34 Nm (350 kg.cm, 25 ft. lbs.)
(b) Remove the Caliper from the torque plate.
4. Remove these parts:
^ 2 Brake Pads with anti-squeal shims.
^ 2 pad support plates.

DISASSEMBLY





1. Remove set ring and cylinder boot.
- Using a screwdriver, remove the set ring and cylinder boot from the Caliper.





2. Remove piston.
(a) Place a piece of cloth, or similar, between the piston and the caliper.
(b) Use compressed air to remove the piston from the cylinder.

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





3. Remove piston seal.
- Using a screwdriver, remove the piston seal from the cylinder.





4. Remove sliding pins and dust boots.
(a) Remove the 2 sliding pins from the torque plate.

CAUTION: Insert the sliding pin with sliding bushing into the top side.

(b) Using a screwdriver and hammer, tap out the 2 dust boots.

NOTE: Use a 24 mm socket wrench and tap in 2 new dust boots into the torque plate.

CAUTION: Confirm that the metal plate portion of the dust boot fits snugly in the torque plate.

REASSEMBLY
Reassembly is in the reverse order of disassembly.

CAUTION: Apply lithium soap base glycol grease to the parts indicated by arrows in EXPLODED VIEW.

INSTALLATION
Installation is in the reverse order of removal.

NOTE: After installation, fill brake reservoir with brake fluid, bleed brake system and check for leaks. Brake Bleeding