Disassembly

BRAKE: FRONT BRAKE: DISASSEMBLY

1. REMOVE ANTI-SQUEAL SPRING (w/ Anti-squeal Spring)

(a) Remove the 2 anti-squeal springs.

2. REMOVE FRONT BRAKE PAD

(a) Remove the 2 brake pads from the front disc brake cylinder mounting.

3. REMOVE FRONT ANTI-SQUEAL SHIM

(a) Remove the 2 anti-squeal shims and the 2 pad wear indicator plates from each pad.

4. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE

(a) Remove the 4 front disc brake pad support plates.

5. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING

(a) Remove the 2 bolts and front disc brake cylinder mounting.





6. REMOVE NO. 1 FRONT DISC BRAKE CYLINDER SLIDE PIN

(a) Remove the No. 1 front disc brake cylinder slide pin from the front disc brake cylinder mounting.





7. REMOVE NO. 2 FRONT DISC BRAKE CYLINDER SLIDE PIN

(a) Remove the No. 2 front disc brake cylinder slide pin from the front disc brake cylinder mounting.

8. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSHING

(a) Using a screwdriver, remove the cylinder slide bushing from the No. 2 front disc brake cylinder slide pin.





NOTICE:
Do not damage the No. 2 front disc brake cylinder slide pin.

HINT
Tape the screwdriver tip before use.

9. REMOVE FRONT DISC BRAKE BUSHING DUST BOOT

(a) Remove the 2 bushing dust boots from the front disc brake cylinder mounting.





10. REMOVE CYLINDER BOOT (for TMC Made)

(a) Using a screwdriver, remove the cylinder boot set ring and the cylinder boot.

NOTICE:
Be careful not to damage the brake piston and cylinder.





11. REMOVE CYLINDER BOOT (for TMMK Made)

(a) Using a screwdriver, remove the cylinder boot.





NOTICE:
Be careful not to damage the brake piston and cylinder.

12. REMOVE FRONT DISC BRAKE PISTON

(a) Prepare a wooden plate to hold the pistons.





(b) Place the wooden plate between the piston and the disc brake cylinder assembly.

(c) 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.

13. 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.

14. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP

(a) Remove the front disc brake bleeder plug cap.

15. REMOVE FRONT DISC BRAKE BLEEDER PLUG

16. REMOVE FRONT DISC

(a) Remove the front disc.





HINT
Put matchmarks on the disc and the axle hub.