Reassembly

BRAKE: FRONT BRAKE: REASSEMBLY

1. INSTALL FRONT DISC

(a) Align the matchmarks and install the front disc.





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

2. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG

(a) Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder assembly.

3. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP

(a) Install the bleeder plug cap to the front disc brake bleeder plug.

4. INSTALL PISTON SEAL

(a) Apply a light layer of lithium soap base glycol grease to the entire circumference of a new piston seal.





(b) Install the piston seal to the disc brake cylinder assembly.

5. INSTALL FRONT DISC BRAKE PISTON (for TMC Made)

(a) Apply a light layer of lithium soap base glycol grease to the entire circumference of a new cylinder boot.





(b) Install the cylinder boot to the front disc brake piston.

(c) Apply a light layer of lithium soap base glycol grease to the contact surfaces of the front disc brake piston, and install it to the disc brake cylinder assembly.

NOTICE:
Do not install the front disc brake piston forcibly in the disc brake cylinder assembly.

6. INSTALL CYLINDER BOOT (for TMC Made)

(a) Install the cylinder boot to the disc brake cylinder assembly.





NOTICE:
Install the boot securely to the grooves of the cylinder and piston.

(b) Using a screwdriver, install a new set ring.

NOTICE:
* Install the set ring securely to the grooves of the cylinder boot.
* Do not damage the cylinder boot.

HINT
Tape the screwdriver tip before use.

7. INSTALL CYLINDER BOOT (for TMMK Made)

(a) Apply a light layer of lithium soap base glycol grease to the entire circumference of a new cylinder boot and front disc brake piston.





(b) Install the cylinder boot to the piston as shown in the illustration.





8. INSTALL FRONT DISC BRAKE PISTON (for TMMK Made)

(a) Install the cylinder boot to the cylinder assembly.





NOTICE:
Install the boot securely to the grooves of the cylinder.

(b) Push in the piston by hand and install the boot seal onto the grooves of the piston.

NOTICE:
Install the boot securely to the grooves of the piston.

9. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT

(a) Apply a light layer of lithium soap base glycol grease to the contact and inner surface of 2 new front disc brake bushing dust boots.





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

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





10. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSHING

(a) Apply a light layer of lithium soap base glycol grease to the contact surface of the No. 2 front disc brake cylinder slide pin.





(b) Install a new front disc brake cylinder slide bushing to the No. 2 front disc brake cylinder slide pin.

11. INSTALL NO. 2 FRONT DISC BRAKE CYLINDER SLIDE PIN

(a) Apply a light layer of lithium soap base glycol grease to the sliding and sealing surfaces of the No. 2 front disc brake cylinder slide pin.





(b) Install the No. 2 front disc brake cylinder slide pin to the bottom side of the cylinder mounting.





12. INSTALL NO. 1 FRONT DISC BRAKE CYLINDER SLIDE PIN

(a) Apply a light layer of lithium soap base glycol grease to the sliding and sealing surfaces of the No. 1 front disc brake cylinder slide pin.





(b) Install the No. 1 front disc brake cylinder slide pin to the top side of the front disc brake cylinder mounting.





13. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING

(a) Install the cylinder mounting with the 2 bolts.





Torque : 107 Nm (1,090 kgf-cm, 79 ft-lbf)

14. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE

15. INSTALL FRONT ANTI-SQUEAL SHIM

(a) Apply disc brake grease to the anti-squeal shims.





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.
* Apply disc brake grease to the area that contacts the anti-squeal shim.
* Disc brake grease can come out slightly from the area where the anti-squeal shim is installed.
* Make sure that disc brake grease is not applied onto the lining surface.

(b) Install the 2 anti-squeal shims and the 2 pad wear indicators to the pads.





NOTICE:
Install the pad wear indicators in the correct positions and directions.

16. INSTALL FRONT BRAKE PAD

(a) Install the 2 brake pads with anti-squeal shims to the disc brake cylinder mounting.

17. INSTALL ANTI-SQUEAL SPRING (w/ Anti-squeal Spring)

(a) Install the 2 anti-squeal springs to the front disc brake pads.





NOTICE:
* When replacing worn pads, the front anti-squeal springs must be replaced at the same time.
* Be sure to install the anti-squeal springs into the front disc brake pad installation holes as far as they will go.