Installation

BRAKE (FRONT): FRONT BRAKE: INSTALLATION

HINT
* Use the same procedure for the LH side and RH side.
* The following procedure listed is for the LH side.

1. INSTALL FRONT DISC

(a) Align the matchmarks of the disc and axle hub, and install the front disc.





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NOTICE:
When replacing the disc with a new one, select the installation position where the front disc has the minimal runout.

2. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING

(a) Install the disc brake cylinder mounting to the steering knuckle with the 2 bolts.

Torque : 107 Nm (1089 kgf-cm, 79 ft-lbf)

3. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT

(a) Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new front disc brake bushing dust boots as shown in the illustration.





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HINT
Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol grease to each front disc brake bush dust boot.

(b) Install the 2 front disc brake bushing dust boots to the disc brake cylinder mounting.

4. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN

(a) Apply a light layer of lithium soap base glycol grease to the entire circumference of the 2 front disc brake cylinder slide pins as shown in the illustration.





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(b) Install the 2 front disc brake cylinder slide pins to the disc brake cylinder mounting.

5. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE

(a) Install the No. 1 front disc brake pad support plate and No. 2 front disc brake pad support plate to the disc brake cylinder mounting.





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NOTICE:
Be sure to install each front disc brake pad support plate in the correct position and direction.

6. INSTALL FRONT ANTI SQUEAL SHIM KIT

(a) Install the 2 No. 1 front anti squeal shims and No. 2 front anti squeal shim to each brake pad.





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NOTICE:
* When replacing worn pads, the anti squeal shims must be replaced together with the pads.
* Install the shims in the correct positions and directions.

7. INSTALL FRONT DISC BRAKE PAD KIT

(a) Install the 2 disc brake pads to the disc brake cylinder mounting.

NOTICE:
There should be no oil or grease on the friction surfaces of the disc brake pads or the front disc.

8. INSTALL DISC BRAKE CYLINDER ASSEMBLY

(a) Hold the front disc brake cylinder slide pin and install the disc brake cylinder assembly to the disc brake cylinder mounting with the 2 bolts.

Torque : 34 Nm (347 kgf-cm, 25 ft-lbf)

9. CONNECT FRONT FLEXIBLE HOSE

(a) Connect the front flexible hose to the disc brake cylinder assembly with a new union bolt and a new gasket.

Torque : 30 Nm (301 kgf-cm, 22 ft-lbf)

HINT
Install the flexible hose lock securely into the lock hole in the disc brake cylinder.

10. BLEED BRAKE LINE

Service and Repair

11. INSTALL FRONT WHEEL

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)