Reassembly

BRAKE: FRONT BRAKE: REASSEMBLY

1. INSTALL FRONT DISC

(a) Aligning the matchmarks, install the front disc.





HINT
Select the installation position where the disc has the minimum runout.

2. INSPECT DISC RUNOUT

(a) Inspect the front axle hub bearing backlash and deviation Front Axle Hub.

(b) Install the disc with the 5 hub nuts.

Torque : 103 Nm (1,050 kgf-cm, 76 ft-lbf)

(c) Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the disc.





Maximum disc runout:

0.05 mm (0.0020 in.)

(d) If the runout exceeds the maximum value, change the installation position of the disc to minimize runout. If the runout exceeds the maximum even when the installation position is changed, grind the disc. If the disc thickness is less than the minimum, replace the disc.

(e) Remove the 5 hub nuts.

3. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG

(a) Temporarily install the front disc brake bleeder plug to the front disc brake cylinder sub-assembly.

4. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP

5. 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 front disc brake cylinder sub-assembly.

NOTICE:
Securely install the piston seal into the groove of the front disc brake cylinder sub-assembly.

6. INSTALL FRONT DISC BRAKE PISTON

(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 front disc brake cylinder sub-assembly.

NOTICE:
Do not install the piston forcibly into the front disc brake cylinder sub-assembly.

7. INSTALL CYLINDER BOOT

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





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

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

NOTICE:
Do not damage the cylinder boot.

8. INSTALL FRONT DISC BRAKE BUSH DUST BOOT

(a) Using soft jaws on a vise, hold the front disc brake cylinder mounting LH in the vise through aluminum plates.

(b) Place the front disc brake cylinder mounting LH in the vise.

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





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

(d) Using a socket wrench (19 mm) and hammer, drive the 2 front disc brake bush dust boots to the front disc brake cylinder mounting LH.