Front

FRONT BRAKE

COMPONENTS:

REMOVAL
1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.

3. DISCONNECT FRONT FLEXIBLE HOSE
(a) Remove the union bolt and the gasket(s) from the disc brake cylinder assembly, then disconnect the flexible hose.





4. REMOVE DISC BRAKE CYLINDER ASSEMBLY LH
(a) Hold the cylinder slide pin (No.1) and cylinder side pin (No.2), and remove the 2 bolts.
(b) Remove the disc brake cylinder assembly.

5. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Remove the 2 disc brake pads with anti-squeal shims from the cylinder mounting LH.

6. REMOVE ANTI SQUEAL SHIM KIT FRONT
(a) Remove the 2 anti-squeal shims from the pads.
(b) Using a screwdriver, remove the 2 pad wear indicator plates from the pads.

7. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Remove the pad support plate (No.1) from the cylinder mounting LH.

8. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Remove the pad support plate (No.2) from the cylinder mounting LH.





9. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Remove the cylinder slide pin (No.1) and cylinder slide pin (No.2) from the cylinder mounting LH.





10. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH
(a) Using a screwdriver, remove the cylinder slide bush from the cylinder slide pin (No.2).

NOTICE: Do not damage the cylinder slide pin (No.2).

HINT: Tape the screwdriver tip before use.





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

INSTALLATION





1. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Apply lithium soap base glycol grease to the sliding part and the sealing surface of the cylinder slide pin (No.1) and cylinder slide pin (No.2).
(b) Install the cylinder slide pin (No.1) and cylinder slide pin (No.2) to the cylinder mounting LH.
(c) Install the cylinder slide pin (No.2) to the cylinder mounting LH.





2. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
(a) Install the cylinder mounting with the 2 bolts.
Torque: 107 N*m (1,090 kgf/cm, 79 ft. lbs.)

3. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the pad support plate (No.1) to the cylinder mounting LH.

4. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the pad support plate (No.2) to the cylinder mounting LH.





5. INSTALL ANTI SQUEAL SHIM KIT FRONT
(a) Apply disc brake grease to the anti-squeal shims and install them to each pad.

NOTICE:
^ When replacing worn pads, replace the antisqueal shims together with the pads.
^ Install the shims in the correct positions and directions.

(b) Install the 2 pad wear indicator plates to the pads.

6. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Install the disc brake pads with anti-squeal shims to the cylinder mounting LH.

NOTICE:
^ There should be no oil or grease on the friction surface of the pads and the disc.
^ Install the brake pads with indicator plates facing upward.





7. INSTALL BRAKE CYLINDER ASSEMBLY LH
(a) Install the disc brake cylinder assembly with the 2 bolts.
Torque: 34 N*m (350 kgf/cm, 25 ft. lbs.)

8. INSTALL FRONT FLEXIBLE HOSE
(a) Connect the flexible hose with the union bolt and new gasket(s).
Torque: 29 N*m (300 kgf/cm, 22 ft. lbs.)

NOTICE: Install the flexible hose lock securely in the lock hole in the disc brake cylinder assembly.

9. FILL RESERVOIR WITH BRAKE FLUID
10. BLEED BRAKE LINE
11. CHECK FLUID LEVEL IN RESERVOIR
12. INSPECT FOR FLUID LEAK
13. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf/cm, 76 ft. lbs.)