Disassembly

BRAKE: FRONT BRAKE: DISASSEMBLY

DISASSEMBLY

1. REMOVE FRONT BRAKE PAD
(a) Remove the 2 anti-squeal springs.
(b) Remove the 2 brake pads from the front disc brake cylinder mounting.
2. REMOVE FRONT ANTI-SQUEAL SHIM
(a) Remove the 2 anti-squeal shims and the 2 pad wear indicators from each pad.
3. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Remove the 4 front disc brake pad support plates from the front disc brake cylinder mounting.
4. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING





(a) Remove the 2 bolts and front disc brake cylinder mounting from the steering knuckle.
5. REMOVE NO. 1 FRONT DISC BRAKE CYLINDER SLIDE PIN





(a) Remove the No. 1 front disc brake cylinder slide pin from the front disc brake cylinder mounting.
6. REMOVE NO. 2 FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Remove the No. 2 front disc brake cylinder slide pin from the front disc brake cylinder mounting.
7. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSHING





(a) Using a screwdriver, remove the front disc brake cylinder slide bushing from the No. 2 front disc brake cylinder slide pin.
NOTE:
Do not damage the No. 2 front disc brake cylinder slide pin.
HINT: Tape the screwdriver tip before use.

8. REMOVE FRONT DISC BRAKE BUSHING DUST BOOT





(a) Remove the 2 front disc brake bushing dust boots from the front disc brake cylinder mounting.
9. REMOVE CYLINDER BOOT





(a) Using a screwdriver, remove the cylinder boot set ring and the cylinder boot.
NOTE:
Be careful not to damage the brake piston and cylinder.

10. REMOVE FRONT DISC BRAKE PISTON





(a) Prepare a wooden plate to hold the front disc brake piston.
(b) Place the wooden plate between the front disc brake piston and the disc brake cylinder assembly.





(c) Use compressed air to remove the front disc brake piston from the disc brake cylinder assembly.
CAUTION:
Do not place your fingers in front of the front disc brake piston when using compressed air.
NOTE:
Do not spatter the brake fluid.

11. REMOVE PISTON SEAL





(a) Using a screwdriver, remove the piston seal from the disc brake cylinder assembly.
NOTE:
Do not damage the inner cylinder or cylinder groove.
HINT: Tape the screwdriver tip before use.

12. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
13. REMOVE FRONT DISC BRAKE BLEEDER PLUG
14. REMOVE FRONT DISC





(a) Remove the front disc.
HINT: Put matchmarks on the disc and the axle hub.