Disassembly

BRAKE: FRONT BRAKE: DISASSEMBLY

DISASSEMBLY
HINT:
- Use the same procedure for the RH and LH sides.
- 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
(a) Remove the shims from each pad.
3. REMOVE NO. 1 PAD WEAR INDICATOR PLATE
(a) Remove the indicator plates from the pads.
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.
7. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH





(a) Using a screwdriver, remove the slide bush from the pin (lower).
HINT: Tape the screwdriver tip before use.
NOTE: Be careful not to damage the pin.

8. REMOVE FRONT DISC BRAKE BUSH DUST BOOT





(a) Remove the 2 boots from the mounting.
9. REMOVE CYLINDER BOOT





(a) Using a screwdriver, pry out the set ring and boot.
HINT: Tape the screwdriver tip before use.
NOTE: Be careful not to damage the brake piston and cylinder.

10. REMOVE FRONT DISC BRAKE PISTON





(a) Place a 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.
NOTE: Be careful not to spatter the brake fluid.

11. REMOVE PISTON SEAL





(a) Using a screwdriver, pry out the seal from the cylinder.
HINT: Tape the screwdriver tip before use.
NOTE: Be careful not to damage the inner cylinder and piston seal groove.

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





(a) Put matchmarks on the disc and axle hub.
(b) Remove the disc.