Front

OVERHAUL

HINT:
^ Overhaul the RH side by the same procedures with LH side.

1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately.





3. REMOVE FRONT DISC BRAKE CYLINDER SUB-ASSEMBLY
a. Remove the union bolt and 2 gaskets from the disc brake cylinder, then disconnect the flexible hose.
b. Hold the cylinder slide pin and remove the 2 bolts.
4. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Remove the 2 anti-squeal springs.
b. Remove the 2 brake pads with anti-squeal shims.
c. Remove the anti-squeal shim and inner anti-squeal shim from the each pad.
5. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
6. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
7. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Remove the cylinder slide pins from the disc brake cylinder mounting.
8. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
a. Using a screwdriver and hammer, tap out the 2 dust boots.

NOTICE: At the time of reassembly, please refer to the following item.
Confirm that the metal plate portion of the dust boot fits snugly in the cylinder mounting.

9. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Remove the 2 bolts and front disc brake cylinder mounting LH.
10. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the 2 set rings and cylinder boots.





11. REMOVE FRONT DISC BRAKE PISTON
a. Place a piece of cloth or similar, between the piston and the disc brake cylinder.
b. Use compressed air to remove the 2 pistons from the disc brake cylinder.

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

NOTICE: Do not spatter the brake fluid.





12. REMOVE PISTON SEAL
a. Using a screwdriver, remove the 2 piston seals from the disc brake cylinder.
13. REMOVE FRONT DISC BRAKE BLEEDER PLUG
14. INSPECT BRAKE CYLINDER AND PISTON
a. Check the cylinder bore and piston for rust or scoring.





15. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 11.0 mm (0.433 inch)
Minimum thickness: 1.0 mm (0.039 inch)
16. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
a. Make sure that they have sufficient rebound, no deformation cracks or wear, and have had all rust, dirt and foreign particles cleaned off.
17. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 32.0 mm (1.260 inch)
Minimum thickness: 30.0 mm (1.181 inch)
18. REMOVE FRONT DISC
a. Put matchmarks on the disc and the axle hub.
b. Remove the disc.
19. INSTALL FRONT DISC
a. Aligning the matchmarks, install the front disc.

HINT: When replacing the disc with new one, select the installation position where the disc has the minimum runout.





20. INSPECT DISC RUNOUT
a. Temporarily fasten the disc with hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Using a dial indicator, measure the disc runout 10 mm (0.39 inch) away from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 inch)
c. If the disc's runout is maximum value or greater, check the bearing play in the axial direction and check the axle hub runout. If the bearing play and axle hub runout are not abnormal, adjust the disc runout or grind it on a "On-car" brake lathe.
21. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
a. Temporarily tighten the bleeder plug to the disc brake cylinder.
22. INSTALL PISTON SEAL
a. Apply the lithium soap base glycol grease on the 2 piston seals.
b. Install the 2 piston seals to the disc brake cylinder
23. INSTALL FRONT DISC BRAKE PISTON
a. Apply the lithium soap base glycol grease on the 2 pistons.
b. Install the 2 pistons to the disc brake cylinder.

NOTICE: Do not screw the piston forcefully in the cylinder.

24. INSTALL CYLINDER BOOT
a. Apply the lithium soap base glycol grease on the 2 cylinder boots.
b. Install the 2 cylinder boots to the disc brake cylinder.

HINT: Install the boot securely to the grooves of the cylinder and piston.

c. Using a screwdriver, install the 2 set rings.

NOTICE: Do not damage the cylinder boot.

25. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Install the disc brake cylinder mounting LH with the 2 bolts.
Torque: 118 Nm (1,200 kgf-cm, 87 ft. lbs.)
26. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
a. Apply the lithium soap base glycol grease to seal surface of 2 new dust boots.
b. Install the 2 dust boots to the disc brake cylinder mounting.
27. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Apply the lithium soap base glycol grease to the sliding part and the seal surface of the 2 cylinder slide pins.
b. Install the 2 cylinder slide pins to the disc brake cylinder mounting.
28. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
29. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE





30. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)

NOTICE: When replacing worn pads, the anti-squeal shims must be replaced together with the pads.

a. Apply disc brake grease to both side of each inner anti squeal shim.
b. Install anti-squeal shims to each pad.
c. Install the inner pad with the wear indicator plate facing upward, and install the outer pad.

NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads and the disc.

31. INSTALL FRONT DISC BRAKE CYLINDER SUB-ASSEMBLY
a. Install the disc brake cylinder with the 2 bolts.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
b. Install 2 new gaskets and flexible hose with the union bolt.
Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.)

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

32. FILL RESERVOIR WITH BRAKE FLUID
33. BLEED MASTER CYLINDER
SST 09023-00100
34. BLEED BRAKE LINE
35. CHECK FLUID LEVEL IN RESERVOIR
36. CHECK BRAKE FLUID LEAKAGE
37. INSTALL FRONT WHEEL
a. Install the front wheel with the 5 nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Install the ornament with the 10 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)