Front

FRONT BRAKE

COMPONENTS:

DISASSEMBLY





1. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the 4 cylinder boots from the disc brake cylinder.

2. REMOVE FRONT DISC BRAKE PISTON





(a) Prepare a wooden plate to hold the pistons.





(b) Place the plate between the pistons and insert a pad into one side.
(c) Use compressed air to remove the pistons alternately from the disc brake cylinder.

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





3. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the 4 piston seals from the disc brake cylinder.

4. REMOVE FRONT DISC BRAKE BLEEDER PLUG
(a) Remove the front disc brake bleeder plug from the disc brake cylinder.





5. REMOVE FRONT DISC
(a) Put matchmarks on the front disc and the axle hub.
(b) Remove the front disc.

REASSEMBLY
1. INSTALL FRONT DISC
(a) Align the matchmarks, and then 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.

2. TEMPORARILY INSTALL FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily install the front disc brake bleeder plug to the disc brake cylinder.

3. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to 4 new piston seals.





(b) Install the 4 piston seals to the disc brake cylinder.

4. INSTALL FRONT DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the 4 front disc brake pistons and 4 new cylinder boots.
(b) Install the 4 cylinder boots to the 4 front disc brake pistons.





(c) Install the 4 pistons to the front disc brake cylinder.

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





5. INSTALL CYLINDER BOOT
(a) Install one side of each of the 4 cylinder boots to the front disc brake cylinder.

NOTICE:
^ Install the boot securely to the grooves of the cylinder and piston.
^ Do not damage the cylinder boot.