Front

FRONT BRAKE

COMPONENTS:

DISASSEMBLY

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

1. 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.





2. 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.





3. 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.

4. REMOVE FRONT DISC BRAKE BLEEDER PLUG
5. REMOVE FRONT DISC
(a) Put matchmarks on the disc and axle hub.
(b) Remove the disc.

REASSEMBLY

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

1. 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 runout.





2. 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 in.) from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 in.)
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 is greater than 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.

3. 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 the "bleed air from brake line" procedures.

(b) Install the cap to the bleeder plug.

4. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to 2 new seals.
(b) Install the 2 seals to the cylinder.

5. 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.

6. INSTALL CYLINDER BOOT
(a) Apply lithium soap base glycol grease to 2 new 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.