Reassembly

BRAKE: FRONT BRAKE: REASSEMBLY

REASSEMBLY

1. INSTALL FRONT DISC





(a) Align the matchmarks and install the front disc.
NOTICE: When replacing the disc with a new one, select the installation position where the front disc has the minimum runout.

2. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder sub-assembly.
3. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
(a) Install the bleeder plug cap to the front disc brake bleeder plug.
4. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder assembly.
5. INSTALL FRONT DISC BRAKE PISTON (for TMC Made)
(a) Apply lithium soap base glycol grease to the piston and a new cylinder boot.





(b) Install the cylinder boot to the piston.
(c) Install the piston to the disc brake cylinder assembly.
NOTICE: Do not install the piston forcibly in the cylinder assembly.

6. INSTALL CYLINDER BOOT (for TMC Made)





(a) Install the cylinder boot to the disc brake cylinder assembly.
NOTICE: Install the boot securely to the grooves of the cylinder and piston.

(b) Using a screwdriver, install a new set ring.
NOTICE:
- Install the set ring securely to the grooves of the cylinder boot.
- Do not damage the cylinder boot.
HINT: Tape the screwdriver tip before use.

7. INSTALL CYLINDER BOOT (for TMMK Made)
(a) Apply lithium soap base glycol grease to the piston and a new cylinder boot.





(b) Install the cylinder boot to the piston as shown in the illustration.
8. INSTALL FRONT DISC BRAKE PISTON (for TMMK Made)





(a) Install the cylinder boot to the cylinder assembly.
NOTICE: Install the boot securely to the grooves of the cylinder.

(b) Push in the piston by hand and install the boot seal onto the grooves of the piston.
NOTICE: Install the boot securely to the grooves of the piston.

9. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT





(a) Apply lithium soap base glycol grease to the seal surface of 2 new bushing dust boots.
(b) Install the 2 bushing dust boots to the front disc brake cylinder mounting.
10. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSHING





(a) Apply lithium soap base glycol grease to a new front disc brake cylinder slide bushing.
(b) Install the front disc brake cylinder slide bushing to the No. 2 front disc brake cylinder slide pin.
11. INSTALL NO. 2 FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Apply lithium soap base glycol grease to the sliding part and the seal surface of the No. 2 front disc brake cylinder slide pin.





(b) Install the No. 2 front disc brake cylinder slide pin to the bottom side of the cylinder mounting.
12. INSTALL NO. 1 FRONT DISC BRAKE CYLINDER SLIDE PIN





(a) Apply lithium soap base glycol grease to the sliding part and the seal surface of the No. 1 front disc brake cylinder slide pin.





(b) Install the No. 1 front disc brake cylinder slide pin.
13. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING





(a) Install the cylinder mounting with the 2 bolts.
Torque: 107 Nm (1,090 kgf-cm, 79ft-lbf)
14. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
15. INSTALL FRONT ANTI-SQUEAL SHIM





(a) Apply disc brake grease to the anti-squeal shims.
NOTICE:
- When replacing worn pads, the anti-squeal shims must be replaced together with the pads.
- Install the shims in the correct positions and directions.
- Apply disc brake grease to the area that contacts the anti-squeal shim.
- Disc brake grease can come out slightly from the area where the anti-squeal shim is installed.
- Make sure that disc brake grease is not applied onto the lining surface.





(b) Install the 2 anti-squeal shims and the 2 pad wear indicators to each pad.
NOTICE: Install the pad wear indicators in the correct positions and directions.

16. INSTALL FRONT BRAKE PAD
(a) Install the 2 brake pads with anti-squeal shims to the disc brake cylinder mounting.
17. INSTALL ANTI-SQUEAL SPRING (w/ Anti-squeal Spring)





(a) Install the 2 anti-squeal springs to the front disc brake pads.
NOTICE:
- When replacing worn pads, the front anti-squeal springs must be replaced at the same time.
- Be sure to install the anti-squeal springs into the front disc brake pad installation holes as far as they will go.