Front

FRONT BRAKE

COMPONENTS:

REMOVAL

HINT:
^ Use the same procedures for the LH side and RH side.
^ The procedures listed below 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 DISC BRAKE CYLINDER ASSEMBLY LH
(a) Remove the union bolt and 2 gaskets from the cylinder, and 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.

INSTALLATION

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 BRAKE CYLINDER MOUNTING LH
(a) Install the mounting with the 2 bolts.
Torque: 118 N*m (1,200 kgf*cm, 87 ft.*lbf)

2. 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.

3. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Apply lithium soap base glycol grease to the sliding parts and seal surfaces of the 2 pins and slide bushing.
(b) Install the slide bushing to the lower slide pin, and then install the 2 pins to the mounting.

4. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE





5. 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 replaced 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.

6. INSTALL DISC BRAKE CYLINDER ASSEMBLY LH
(a) Install the cylinder with the 2 bolts.
Torque: 34 N*m (350 kgf*cm, 25 ft.*lbf)
(b) Install 2 new gaskets and the flexible hose with the union bolt.
Torque: 30 N*m (310 kgf*cm, 22 ft.*lbf)

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

7. FILL RESERVOIR WITH BRAKE FLUID
8. BLEED AIR FROM BRAKE LINE
9. CHECK BRAKE FLUID LEVEL IN RESERVOIR
10. CHECK FOR BRAKE FLUID LEAKAGE
11. INSTALL FRONT WHEEL
(a) Install the wheel with the 5 nuts.
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
(b) Install the ornament with the 10 bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)