Front Disc Brake Assembly

DISASSEMBLY
16-INCH TYPE
1. Remove mud and foreign matter from the caliper body assembly and the support.

CAUTION: Be careful not to allow foreign matter to enter the brake hose connector.

2. Place a wooden block in the caliper body as shown in the figure to prevent the piston from jumping out and being damaged.
3. Gradually apply compressed air via the brake hose installation hole to push the piston out.





4. Remove the piston boot.





5. Remove the piston seal from caliper body cylinder.

CAUTION: Do not damage the cylinder and piston seal groove.





6. Remove the guide pin and boot from caliper body.

17-INCH TYPE
Refer to 16-inch type.

ASSEMBLY
16-INCH TYPE
1. Clean the inside of the caliper body using brake fluid.
2. Apply a coat of brake fluid to piston seal and install the piston seal to the caliper body groove.
3. Apply a coat of brake fluid to the inner surface of cylinder and the entire outer surface of the piston.
4. Apply grease contained in the piston seal kit to the boot, and install it to the groove at the end of the cylinder.
5. Insert the piston into cylinder.

CAUTION: Do not force the piston into cylinder.





6. Position the boot in the grooves on cylinder and piston.





7. Apply grease contained in the piston seal kit to the lock pin, guide pin outer surface, cylinder inner surface, and boot grooves.
8. Insert the lock pin and guide pin boot into the support.





CAUTION: After inserting the lock pin and guide pin into the specified locations, check by hand that the pin moves and slides smoothly with no abnormalities when it reaches the end.

17-INCH TYPE
Refer to 16-inch type.

INSPECTION
1. Repair or replace the faulty parts.
2. Check the caliper body and piston for uneven wear, damage or rust.
3. Check the rubber parts for damage or deterioration.