Front

FRONT BRAKE

COMPONENTS:

DISASSEMBLY





1. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the 4 cylinder boots from the caliper.





2. REMOVE FRONT DISC BRAKE PISTON
(a) Prepare the wooden plate to hold the pistons.





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

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





3. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the 4 piston seals from the cylinder.
4. REMOVE FRONT DISC BRAKE BLEEDER PLUG
(a) Remove the breeder plug cap and breeder plug from the disc brake cylinder assembly.
5. INSPECT BRAKE CYLINDER AND PISTON
6. INSPECT PAD LINING THICKNESS
7. INSPECT DISC THICKNESS
8. REMOVE FRONT DISC
(a) Make matchmarks on the disc and the axle hub.
(b) Remove the front disc.

REASSEMBLY
1. INSTALL FRONT DISC
(a) Aligning the matchmarks, install the front disc.

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

2. INSPECT DISC RUNOUT
3. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily tighten the bleeder plug to the disc brake cylinder assembly.
(b) Install the breeder plug cap to the breeder plug.
4. INSTALL PISTON SEAL
(a) Apply the lithium soap base glycol grease to the 4 new piston seals.
(b) Install the 4 piston seals to the disc brake cylinder assembly.
5. INSTALL FRONT DISC BRAKE PISTON
(a) Apply the lithium soap base glycol grease to the 4 disc brake pistons.
(b) Install the 4 disc brake pistons on the disc brake cylinder assembly.

NOTICE: Do not screw the disc brake piston forcedly in the disc brake cylinder assembly.

6. INSTALL CYLINDER BOOT
(a) Apply the lithium soap grease glycol grease to the 4 new cylinder boots.
(b) Install the 4 cylinder boots on the disc brake cylinder assembly.

HINT: Install the cylinder boot securely on the grooves of the disc brake cylinder and piston.