Front Brake

OVERHAUL

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

1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Wash off brake fluid immediately if it comes in contact with any painted surface.

3. REMOVE FRONT DISC BRAKE CYLINDER SUB-ASSEMBLY
a. Remove the union bolt and 2 gaskets from the cylinder, then disconnect the flexible hose.





b. Hold the upper slide pin and remove the bolt. Then hold the lower slide pin and remove the bolt.
4. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Remove the 2 anti-squeal springs.
b. Remove the 2 pads with anti-squeal shims.
c. Remove the shim and inner shim from each pad.
5. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
6. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Remove the pins from the brake cylinder mounting.





7. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
a. Using a screwdriver and hammer, tap out the 2 boots.
8. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Remove the 2 bolts and mounting.
9. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the 2 set rings and boots.

NOTICE: Be careful not to damage the brake piston and cylinder.





10. REMOVE FRONT DISC BRAKE PISTON
a. Place a piece of cloth or equivalent between the piston and cylinder.
b. Use compressed air to remove the 2 pistons from the cylinder.

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

NOTICE: Be careful not to spatter the brake fluid.





11. REMOVE PISTON SEAL
a. Using a screwdriver, pry out the 2 seals from the cylinder.

NOTICE: Be careful not to damage the inner cylinder and cylinder groove.

12. REMOVE FRONT DISC BRAKE BLEEDER PLUG
13. INSPECT BRAKE CYLINDER AND PISTON
a. Check the cylinder bore and piston for rust or scoring. If necessary, replace the cylinder and piston.





14. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 11.0 mm (0.433 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the pad lining thickness is equal to or less than the minimum, replace the pad.
15. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
a. Check the 4 plates.

HINT: Make sure that the plates have sufficient rebound and are free from deformation, cracks, wear, rust and dirt.

If necessary, replace the plates.
16. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 32.0 mm (1.260 inch)
Minimum thickness: 30.0 mm (1.181 inch)
If the disc thickness is less than the minimum, replace the disc.
17. REMOVE FRONT DISC
a. Put matchmarks on the disc and axle hub.
b. Remove the disc.
18. INSTALL FRONT DISC
a. Align the matchmarks and install the disc.

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





19. INSPECT DISC RUNOUT
a. Check the bearing play in the axial direction and check the axle hub runout.
b. Temporarily fasten the disc with hub nuts.
c. Using a dial indicator, measure the disc runout 10 mm (0.39 inch) away from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 inch)
If the runout is greater than the maximum, change the installation positions of the disc and axle so that the runout is as small as possible.
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 disc.
d. Remove the 2 hub nuts.
20. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
a. Install the bleeder plug to the cylinder.

HINT: The bleeder plug will be tightened to a torque specification in step 33.

21. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to the 2 seals.
b. Install the 2 seals to the cylinder.
22. INSTALL FRONT DISC BRAKE PISTON
a. Apply lithium soap base glycol grease to the 2 pistons.
b. Install the 2 pistons to the cylinder.

NOTICE: Do not install the piston forcibly to the cylinder.

23. INSTALL CYLINDER BOOT
a. Apply lithium soap base glycol grease to the 2 boots.
b. Install the 2 boots to the cylinder.

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

c. Using a screwdriver, install the 2 set rings.

NOTICE: Be careful not to damage the cylinder boot.

24. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Install the mounting with the 2 bolts.
Torque: 118 Nm (1,200 kgf-cm, 87 ft. lbs.)
25. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
a. Apply lithium soap base glycol grease to the seal surfaces of 2 new boots.
b. Install the 2 boots to the mounting.

NOTICE: Confirm that the metal plate portion of the dust boot fits snugly in the mounting.

26. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Apply lithium soap base glycol grease to the sliding parts and the seal surfaces of the 2 pins.
b. Install the 2 pins to the disc mounting.
27. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE





28. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Apply disc brake grease to both sides of each anti-squeal shim.
b. Install the shims on each pad.

NOTICE:
^ When replacing a worn pad, the shims must be re place together with the pad.
^ Install the shims in the correct positions and direction.

c. Install the pad wear indicator to each pad.
d. Install the pad to the mounting.

NOTICE: There should be no oil or grease on the friction surface of the pads and disc.

29. INSTALL FRONT DISC BRAKE CYLINDER SUB-ASSEMBLY
a. Install the cylinder with the 2 bolts.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
b. Install 2 new gaskets and the flexible hose with the union bolt.
Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.)

HINT: Install the flexible hose lock securely in the lock hole in the cylinder.

30. FILL RESERVOIR WITH BRAKE FLUID
31. BLEED AIR FROM BRAKE LINE
32. CHECK FLUID LEVEL IN RESERVOIR
33. CHECK BRAKE FLUID LEAKAGE
34. INSTALL FRONT WHEEL
a. Install the wheel with the 5 nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Install the ornament with the 10 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)