Front

REMOVAL AND INSTALLATION

Front Disc Brake Assembly:

NOTE: When overhauling the disc brakes, overhaul both sides (left and right) as a set.

1. Remove the brake hose connection and gasket.
2. Remove the brake assembly.
3. Remove the disc/rotor and check for damage.

DISASSEMBLY

Caliper Assembly:

1. Remove the guide pin and lock pin.
2. Remove the bushing and caliper support (pad, clip and shim.)
3. Remove the boot and boot ring.





4. Remove the piston boot and piston. Pump in compressed air through the brake hose installation hole and remove the pistons and piston boot.

CAUTION: When removing the pistons, be sure to use the handle of a plastic hammer and adjust the height of the two pistons while slowly pumping in air, so that the pistons protrude evenly. Do not remove one piston completely before trying to remove the other piston. It will become impossible to remove the second piston.

Remove Piston Seal:

5. Remove piston seal with fingertip.

CAUTION: Do not use a flat-tipped screwdriver or other tool to prevent damage to inner cylinder.

6. Remove the caliper body.

CAUTION: Clean piston surface and inner cylinder with trichloro-ethylene, alcohol, DOT 3 or DOT 4 brake fluid.

LUBRICATION POINTS

Lubrication Points On Caliper Assembly:

- Refer to the illustration for lubrication points.

ASSEMBLY
1. Reverse disassembly procedure to install, noting the following:

Lubrication Points On Caliper:

2. When installing the boot, bushing, lock pin and guide pin grease all parts as illustrated with specified grease, (orange repair kit grease.)





3. Install the guide pin and lock pin as illustrated and ensure that the head mark of the guide pin "G" and the lock pin "L" matches the indication mark ("G" or "L") located on the caliper body.