Disc Brake System: Service and Repair

FRONT BRAKE

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. REMOVE FRONT DISC BRAKE CYLINDER SUBASSEMBLY LH
a) Remove the union bolt and gasket from the front disc brake cylinder, and then disconnect the flexible hose.

b) Hold the brake cylinder slide pin, and remove the 2 bolts and brake cylinder.
4. REMOVE FRONT DISC BRAKE PAD
a) Remove the 2 pads with anti squeal shims.
5. REMOVE FRONT ANTI SQUEAL SHIM
a) Remove the No. 1 and No. 2 shims from each pad.
6. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
a) Remove the 2 support plates from the cylinder mounting.

7. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
a) Remove the 2 slide pins from the cylinder mounting.

8. REMOVE FRONT DISC BRAKE DUST BOOT
a) Remove the 2 bush dust boots from the cylinder mounting.

9. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH
a) Remove the 2 bolts and cylinder mounting.

10. REMOVE FRONT DISC
a) Place matchmarks on the disc and axle hub.
b) Remove the disc.

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 set ring and cylinder boot.

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

2. REMOVE FRONT DISC BRAKE PISTON
a) Place a cloth between the brake piston and brake cylinder.
b) Use compressed air to remove the piston from the cylinder.

CAUTION: Do not place your fingers 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, pry out the piston seal from the brake 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 from the brake cylinder.

REASSEMBLY

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

1. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
a) Install the bleeder plug to the brake cylinder.

HINT: The bleeder plug will be tightened to a torque specification in the bleed air from brake line procedures.

b) Install the bleeder plug cap.
2. INSTALL PISTON SEAL
a) Apply lithium soap base glycol grease to a new piston seal.
b) Install the piston seal to the brake cylinder.

3. INSTALL FRONT DISC BRAKE PISTON
a) Apply lithium soap base glycol grease to the brake piston and a new cylinder boot.
b) Install the cylinder boot to the brake piston.
c) Install the piston (with boot) to the brake cylinder.

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

4. INSTALL CYLINDER BOOT
a) Install the cylinder boot to the brake cylinder.

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

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 FRONT DISC
a) Align the matchmarks and install the disc.

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

2. CHECK DISC RUNOUT
a) Check the bearing play in the axial direction and check the axle hub runout.
b) Temporarily install the disc to the hub with the hub nuts.
c) Using a dial indicator, measure the disc runout 10.0 mm (0.39 inch) from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 inch)
If the runout is greater than the maximum, change the installation positions of the disc and axle so that the runout will become minimal.
If the runout is greater than the maximum even when the installation positions are changed, grind the disc.
If the disc thickness is less than the minimum, replace the disc.
d) Remove the 2 hub nuts.

3. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
a) Install the cylinder mounting with the 2 bolts.
Torque: 88 Nm (900 kgf-cm, 65 ft. lbs.)

4. INSTALL FRONT DISC BRAKE DUST BOOT
a) Apply lithium soap base glycol grease to the contact surface of the 2 bush dust boots.
b) Install the 2 bush dust boots to the cylinder mounting.

5. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
a) Apply lithium soap base glycol grease to the sliding part and contact surface of the 2 slide pins.
b) Install the 2 slide pins to the cylinder mounting.
6. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
a) Install the 2 support plates to the cylinder mounting.

7. INSTALL FRONT ANTI SQUEAL SHIM
a) Apply disc brake grease to the both sides of each No. 1 shim.
b) Install the No. 1 and No. 2 shims to each pad.

NOTICE:
^ When replacing worn pad, the shims must be replaced together with the pads.
^ Install the shims in the correct positions and direction.

8. INSTALL FRONT DISC BRAKE PAD
a) Install the 2 brake pads to the cylinder mounting.

NOTICE: There should be no oil or grease on the friction surfaces of the pads and disc.

9. INSTALL FRONT DISC BRAKE CYLINDER SUBASSEMBLY LH
a) Install the brake cylinder with the 2 bolts.
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)

b) Connect the flexible hose with a new gasket and the union bolt.
Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.)

HINT: Install the flexible hose lock securely in the lock hole in the brake cylinder.

10. FILL RESERVOIR WITH BRAKE FLUID
11. BLEED AIR FROM BRAKE MASTER CYLINDER
12. BLEED AIR FROM BRAKE LINE
13. CHECK BRAKE FLUID LEVEL IN RESERVOIR
14. CHECK FOR BRAKE FLUID LEAKAGE
15. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)