Front
FRONT BRAKECOMPONENTS:
DISASSEMBLY
HINT:
^ Use the same procedures for the LH side and RH side.
^ The procedures listed below are for the LH side.
1. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the cylinder boot from the disc brake caliper.
2. REMOVE FRONT DISC BRAKE PISTON
(a) Prepare a wooden plate to hold the pistons.
(b) Place the plate between the pistons and insert a pad into one side.
(c) Use compressed air to remove the pistons alternately from the disc brake caliper.
CAUTION: Do not place your fingers in front of the pistons when using compressed air.
3. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the 4 piston seals from the disc brake caliper.
4. REMOVE FRONT DISC BRAKE BLEEDER PLUG
(a) Remove the bleeder plug from the disc brake caliper.
5. REMOVE FRONT DISC
(a) Put matchmarks on the front disc and axle hub.
(b) Remove the front disc.
REASSEMBLY
HINT:
^ Use the same procedures for the LH side and RH side.
^ The procedures listed below are for the LH side.
1. INSTALL FRONT DISC
(a) Align the matchmarks, and install the front disc.
HINT: When replacing the front disc with a new one, select the installation position where the front disc has the minimum runout.
2. TEMPORARILY INSTALL FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily install the bleeder plug to the disc brake caliper.
3. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to 4 new piston seals.
(b) Install the 4 piston seals to the disc brake caliper.
4. INSTALL FRONT DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the front disc brake piston and a new cylinder boot.
(b) Install the cylinder boot to the front disc brake piston.
(c) Install the piston into the front disc brake caliper.
NOTICE: Do not forcibly install the piston into the disc brake caliper.
5. INSTALL CYLINDER BOOT
(a) Install a new cylinder boot to the front disc brake caliper.
NOTICE:
^ Install the cylinder boot securely to the grooves of the cylinder and piston.
^ Do not damage the cylinder boot.