Front Disc Brake

FRONT DISC BRAKE


Removal and Installation of Brake Caliper Assembly


WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne particles or other materials.

CAUTION:
- While removing caliper, do not depress brake pedal because piston will pop out.
- It is not necessary to remove bolts on torque member and brake hose except for disassembly or replacement of caliper assembly. In this case, hang caliper with a wire so as not to stretch brake hose.
- Do not damage piston boot.
- If any shim is subject to serious corrosion, replace it with a new one.
- Always replace shim and shim cover as a set when replacing brake pads.
- Keep rotor free from brake fluid.
- Burnish the brake pads and disc rotor mutually contacting surfaces, after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Brake Burnishing.

REMOVAL
1. Remove front wheels and tires using power tools.
2. Secure disc rotor using wheel nuts.





3. Remove union bolt (A), and then disconnect brake hose from cylinder body. Discard the copper washers.
- Protrusions (B)

CAUTION:
Do not reuse the copper washers.

NOTE:
Cap or plug opening(s) to prevent fluid fro spilling.





4. Remove sliding pin bolts (A) and remove cylinder body from torque member.





5. If necessary, apply matching marks then remove wheel nuts and remove disc rotor.

CAUTION:
Put matching marks on wheel hub assembly and disc rotor as shown, if it is necessary to remove disc rotor.

INSTALLATION





1. If removed, install disc rotor and secure using wheel nuts.

CAUTION:
Follow matching marks on wheel hub assembly and disc rotor for installation as shown.





2. Install cylinder body on sliding pins, and tighten sliding pin bolts
(A) to the specified torque. Removal and Replacement.

CAUTION:
Before installing cylinder body, wipe off all oil and grease on mounting surface of torque member.





3. Install brake hose to cylinder body with new copper washers.
Align the brake hose tab between the protrusions (B) on the cylinder body as shown. Tighten the union bolt (A) to specification. Diagrams.

CAUTION:





Do not reuse copper washers.
4. Check front disc brake for drag.
5. Bleed the brake system. Service and Repair.
6. Install front wheels and tires. Adjustment.