Front

FRONT BRAKE

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

DISASSEMBLY

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

1. REMOVE FRONT DISC BRAKE PAD
(a) Remove the 2 disc brake pads.
2. REMOVE ANTI-SQUEAL SHIM KIT FRONT
(a) Remove the shims from each pad.
3. REMOVE NO. 1 PAD WEAR INDICATOR PLATE
(a) Remove the indicator plates from each pad.
4. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Remove the 4 plates from the brake cylinder mounting.

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

6. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Remove the 2 pins (upper and lower) from the mounting.

(b) Using a screwdriver, remove the slide bush from the pin (lower).

NOTICE: Be careful not to damage the pin.

HINT: Tape the screwdriver tip before use.

7. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
(a) Remove the 2 boots from the mounting.

8. REMOVE CYLINDER BOOT
(a) Using a screwdriver, pry out the set ring and boot.

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

HINT: Tape the screwdriver tip before use.

9. REMOVE FRONT DISC BRAKE PISTON
(a) Place a shop rag or piece of cloth between the piston and disc brake cylinder.
(b) Apply compressed air to remove the piston from the disc brake cylinder.

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

NOTICE: Be careful not to spatter the brake fluid.

10. REMOVE PISTON SEAL
(a) Using a screwdriver, pry out the seal from the cylinder.

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

HINT: Tape the screwdriver tip before use.

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

12. REMOVE FRONT DISC
(a) Put matchmarks on the disc and axle hub.
(b) Remove the disc.

REASSEMBLY

HINT:
^ Use the same procedures for the LH side and RH side.
^ The procedures listed below 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 disc has the minimum runout.

2. CHECK DISC RUNOUT
3. 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 bleeder plug cap.
4. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new seal.
(b) Install the seal to the cylinder.

NOTICE: Securely install the piston seal into the groove of the disc brake cylinder.

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

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

6. INSTALL CYLINDER BOOT
(a) Install the cylinder boot to the cylinder.

NOTICE: Securely install the cylinder boot into the groove of the disc brake cylinder.

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

NOTICE: Do not damage the cylinder boot.

HINT: Tape the screwdriver tip before use.

7. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Apply lithium soap base glycol grease to 2 new boots.
(b) Install the 2 boots to the mounting.

8. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Apply lithium soap base glycol grease to the pins and a new bush as shown in the illustration.
(b) Install the bush to the pin (lower).

9. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
(a) Install the cylinder mounting with the 2 bolts.
Torque: 98 Nm (999 kgf-cm, 72 ft. lbs.)
10. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the 4 plates to the mounting.
11. INSTALL NO. 1 PAD WEAR INDICATOR PLATE
(a) Install the 2 indicator plates to the upper side of each pad.

12. INSTALL ANTI-SQUEAL SHIM KIT FRONT
(a) w/ [diameter]275 disc brake:
(1) Apply disc brake grease to both sides of each No. 1 shim.
(2) Install the No. 1 and No. 2 shims to each pad.

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

(b) w/ [diameter]296 disc brake:
(1) Install the No. 1 and No. 2 shims to each pad.

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

13. INSTALL FRONT DISC BRAKE PAD
(a) Install the 2 disc brake pads to the mounting.

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