Disassembly

DISASSEMBLY

1. REMOVE DISC BRAKE PADS WITH ANTI-SQUEAL SHIMS
(a) Remove the 2 brake pads with anti-squeal shims.

2. REMOVE ANTI-SQUEAL SHIMS AND PAD WEAR INDICATOR PLATES
(a) Remove the 2 anti-squeal shims and the 2 pad wear indicator plates from each pad.

3. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE

(a) for Type A:

(1) Remove the 2 front No. 1 disc brake pad support plates and 2 front No. 2 disc brake pad support plates from the front disc brake cylinder mounting.






Text in Illustration






NOTICE:
Each front disc brake pad support plate has a different shape. Be sure to put an identification mark on each front disc brake pad support plate so that they can be installed to their original position.

(b) for Type B:

(1) Remove the front No. 1 disc brake pad support plate and front No. 2 disc brake pad support plate from the front disc brake cylinder mounting.






Text in Illustration






NOTICE:
Each front disc brake pad support plate has a different shape. Be sure to put an identification mark on each front disc brake pad support plate so that they can be installed to their original position.

4. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Remove the cylinder slide pin from the cylinder mounting LH.

5. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSHING
(a) Using a screwdriver, remove the cylinder slide bush from the cylinder slide pin.

HINT:
Tape the screwdriver tip before use.

6. REMOVE NO. 2 FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Remove the cylinder slide pin No. 2 from the cylinder mounting LH.

7. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING
(a) Remove the 2 bolts and cylinder mounting.
(b) Remove the 2 caliper plates No. 1 from the cylinder mounting.

8. REMOVE FRONT DISC BRAKE BUSHING DUST BOOT
(a) Secure the cylinder mounting LH in a vise.





(b) Using a screwdriver and a plastic hammer, remove the 2 bushing dust boots.

9. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the set ring or cylinder boot.

NOTICE:
Do not damage the inner cylinder or cylinder groove.

HINT:
Tape the screwdriver tip before use.






10. REMOVE FRONT DISC BRAKE PISTON
(a) Place a piece of cloth between the piston and the disc brake cylinder assembly.
(b) Use compressed air to remove the piston from the disc brake cylinder assembly.

CAUTION:
Do not place your fingers in front of the piston when using compressed air.

NOTICE:
Do not spatter the brake fluid.






11. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal from the disc brake cylinder assembly.

NOTICE:
Do not damage the inner cylinder or cylinder groove.

HINT:
Tape the screwdriver tip before use.






12. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP

13. REMOVE FRONT DISC BRAKE BLEEDER PLUG

14. REMOVE FRONT DISC
(a) Put matchmarks on the disc and the axle hub.






(b) Remove the front disc.