Front

FRONT BRAKE

COMPONENTS:

COMPONENTS:

REMOVAL

HINT:
^ Use the same procedures for the LH side and RH side.
^ The procedures listed are for the LH side.

1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Wash off brake fluid immediately if it comes in contact with any painted surface.





3. CHECK BRAKE PAD LINING THICKNESS
a. Check the pads' thickness through the cylinder inspection hole.
Minimum thickness: 1.0 mm (0.039 inch)
If the pads' lining thickness is equal to or less than the minimum, replace the pads.





4. REMOVE FRONT DISC BRAKE PAD
a. Remove the clip and 2 pins.
b. Remove the 2 pad retainer clips.
c. Remove the 2 pads, 2 anti squeal shims and 2 pad retainers.

NOTICE: The pad retainer clip and clip can be reused again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off.





5. DISCONNECT FRONT BRAKE FLEXIBLE HOSE
a. Remove the union bolt and 2 gaskets from the cylinder.
b. Disconnect the flexible hose from the cylinder.





6. REMOVE DISC BRAKE CYLINDER ASSEMBLY
a. Remove the 2 mounting bolts, washer and cylinder.

DISASSEMBLY

HINT:
^ Use the same procedures for the LH side and RH side.
^ The procedures listed are for the LH side.





1. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the 4 set rings and 4 boots from the cylinder.

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

2. REMOVE FRONT DISC BRAKE PISTON





a. Prepare a wooden plate to hold the pistons.





b. Place the wooden plate between the pistons and insert a pad on one side.
c. Use compressed air to remove the pistons alternately from the cylinder.

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

NOTICE: Be careful not to spatter the brake fluid.





3. REMOVE PISTON SEAL
a. Using a screwdriver, remove the 4 rings from the cylinder.

NOTICE: Be careful not to damage the inner cylinder and cylinder groove.

4. REMOVE FRONT DISC BRAKE BLEEDER PLUG
a. Remove the bleeder plug cap and bleeder plug from the cylinder.

INSPECTION
1. CHECK BRAKE CYLINDER AND FRONT DISC BRAKE PISTON
a. Check the cylinder bore and piston for rust or scoring.
If necessary, replace the cylinder and piston.





2. CHECK PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 11.5 mm (0.453 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the pad lining thickness is equal to or less than the minimum, replace the pad.





3. CHECK DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 32.0 mm (1.260 inch)
Minimum thickness: 30.0 mm (1.181 inch)
If the disc thickness is less than the minimum, replace the disc.

REASSEMBLY

HINT:
^ Use the same procedures for the LH side and RH side.
^ The procedures listed are for the LH side.





1. CHECK DISC RUNOUT
a. Check the bearing play in the axial direction and check the axle hub deviation.
b. Using a dial indicator, measure the disc runout 10 mm (0.39 inch) away from the outer edge of the disc.
Maximum disc runout: 0.07 mm (0.0028 inch)
If the runout is greater than the maximum, grind the disc. If the disc thickness is less than the minimum, replace the disc.
2. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
a. Install the bleeder plug to the cylinder.

HINT: The bleeder plug will be tightened to a torque specification in the BLEED AIR FROM BRAKE LINE procedures.

b. Install the cap to the bleeder plug.
3. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to 4 new seals.
b. Install the 4 seals to the cylinder.
4. INSTALL FRONT DISC BRAKE PISTON
a. Apply lithium soap base glycol grease to the 4 pistons and 4 new cylinder boots.
b. Install the 4 boots to the pistons.
c. Install the 4 pistons (with the boots) to the cylinder.

NOTICE: Do not forcibly install the pistons to the cylinder.

5. INSTALL CYLINDER BOOT
a. Install 4 new boots to the cylinder.
b. Using a screwdriver, install the set ring.

NOTICE: Be careful not to damage the boot.

INSTALLATION

HINT:
^ Use the same procedures for the LH side and RH side.
^ The procedures listed are for the LH side.





1. INSTALL DISC BRAKE CYLINDER ASSEMBLY
a. inch lbs.)





2. CONNECT FRONT BRAKE FLEXIBLE HOSE
a. Connect the flexible hose with 2 new gaskets and the union bolt.
Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.)
3. INSTALL FRONT DISC BRAKE PAD





a. Press in the piston with a hammer handle or an equivalent.

HINT:
^ Always change the pads on one wheel at a time as there is a possibility of opposite position flying out.
^ If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape.





b. Install the 2 pad retainers to each cylinder piston.
c. Install the anti squeal shims to each pad.

NOTICE: When replacing worn pads, the shims must be replaced together with the pads.

HINT: Apply disc brake grease to both sides of the anti squeal shims.

d. Install the 2 pads.

HINT: Apply disc brake grease to the pads indicated by the arrows.

e. Install the 2 pad retainers, clip and 2 pins.
4. FILL RESERVOIR WITH BRAKE FLUID
5. BLEED AIR FROM HYDRAULIC BRAKE BOOSTER
6. BLEED AIR FROM BRAKE LINE
7. CHECK BRAKE FLUID LEVEL IN RESERVOIR
8. CHECK FOR BRAKE FLUID LEAKAGE
9. INSTALL FRONT WHEEL