Reassembly

BRAKE: FRONT BRAKE: REASSEMBLY

HINT
* Use the same procedure for the RH and LH sides.
* 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 smallest runout.

2. CHECK DISC RUNOUT Front Brake

3. TEMPORARILY INSTALL FRONT DISC BRAKE BLEEDER PLUG

(a) Temporarily 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 a light coat of lithium soap base glycol grease to the entire inner and outer circumference of a new piston seal.





(b) Install the piston 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 a light coat of lithium soap base glycol grease to the inner and outer circumference of a new cylinder boot, as well as the entire circumference of the top and bottom of the outer edge, as shown in the illustration.





(b) Apply a light coat of lithium soap base glycol grease to the entire outer circumference of the front disc brake piston where it contacts the cylinder boot and front disc brake cylinder.

(c) Install the cylinder boot to the front disc brake piston.

6. INSTALL CYLINDER BOOT

(a) Install the front disc brake piston to the front disc brake cylinder.





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

(b) Install the cylinder boot to the cylinder.

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

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

HINT
Tape the screwdriver tip before use.

NOTICE:
Do not damage the cylinder boot.

7. INSTALL FRONT DISC BRAKE BUSH DUST BOOT

(a) Apply a light coat of lithium soap base glycol grease to the entire circumference of a new rear disc brake bush dust boot where it contacts the rear disc brake cylinder mounting, and the entire inner circumference of its both ends.





NOTICE:
Apply a sufficient amount of lithium soap base glycol grease to the entire circumference of the rear disc brake bush dust boot and rear disc brake cylinder mounting contact surfaces.

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

(b) Install the 2 boots to the mounting.

8. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH

(a) Apply a light coat of lithium soap base glycol grease to the contact surface of the front disc brake cylinder slide pin (lower) where it contacts front disc brake cylinder slide bush.





(b) Install a new front disc brake cylinder slide bush to the slide pin (lower).

9. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN

(a) Apply a light coat of lithium soap base glycol grease to the sliding part and the seal surface of the 2 front disc brake cylinder slide pins.





(b) Install the 2 slide pins (upper and lower) to the mounting.





10. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH

(a) Install the cylinder mounting with the 2 bolts.





Torque : 107 Nm (1089 kgf-cm, 79 ft-lbf)

11. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE

(a) Install the 4 plates to the mounting.

12. INSTALL NO. 1 PAD WEAR INDICATOR PLATE

(a) Install the 2 indicator plates to the upper side of the pads.

13. INSTALL ANTI-SQUEAL SHIM KIT FRONT

(a) w/ 10.83 inch Front 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 the pads.

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/ 11.70 inch Front Disc Brake:





(1) Install the No. 1 and No. 2 shims to the pads.

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.
14. INSTALL FRONT DISC BRAKE PAD

(a) Install the 2 disc brake pads to the mounting.

NOTICE:
Make sure there is no oil or grease on the friction surfaces of the pads and disc.