Installation

BRAKE: FRONT BRAKE: INSTALLATION

INSTALLATION





1. INSTALL FRONT DISC
(a) Align the matchmarks of the disc and axle hub and install the disc.
NOTE: When replacing the disc, select the position that gives the minimum disc runout.





2. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING
(a) Install the disc brake cylinder mounting onto the steering knuckle with the 2 bolts.
Torque: 107 Nm (1089 kgf-cm, 79 ft-lbf)






3. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Apply lithium soap base glycol grease to 2 new dust boots.
(b) Install the 2 dust boots onto the disc brake cylinder mounting.






4. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH
(a) Apply lithium soap base glycol grease to the slide pins and a new slide bush, as shown in the illustration.
(b) Install the slide bush onto the No. 2 slide pin.






5. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Install the No. 1 slide pin and No. 2 slide pin onto the cylinder mounting.
NOTE: The No. 1 slide pin is for the upper side and the No. 2 slide pin is for the lower side.





6. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the 4 pad support plates onto the disc brake cylinder mounting.
NOTE: Be sure to install each pad support plate to the correct position and direction.





7. INSTALL FRONT ANTI SQUEAL SHIM
(a) Apply disc brake grease to both sides of each No. 1 anti squeal shim.
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 shims.
- 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 4 anti squeal shims to each brake pad.






8. INSTALL FRONT DISC BRAKE PAD
(a) Install the 2 disc brake pads onto the disc brake cylinder mounting.
NOTE: There should be no oil or grease on the friction surfaces of the disc brake pads or the front disc.





9. INSTALL DISC BRAKE CYLINDER ASSEMBLY
(a) Hold the slide pin slide pin with a spanner and install the disc brake cylinder onto the disc brake cylinder mounting with the 2 bolts.
Torque: 34 Nm (350 kgf-cm, 25 ft-lbf)






10. INSTALL FRONT FLEXIBLE HOSE
(a) Install the flexible hose with the union bolt and a new gasket.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
HINT: Install the flexible hose lock securely into the lock hole in the disc brake cylinder.

11. FILL RESERVOIR WITH BRAKE FLUID Replacement

12. BLEED MASTER CYLINDER Replacement

13. BLEED BRAKE LINE Replacement

14. BLEED BRAKE ACTUATOR Replacement

15. CHECK FLUID LEVEL IN RESERVOIR Replacement

16. INSPECT FOR BRAKE FLUID LEAK
17. INSTALL FRONT WHEEL
Torque: 103 Nm (1050 kgf-cm, 76 ft-lbf)