Reassembly

BRAKE: FRONT BRAKE: 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 a light layer of lithium soap base glycol grease to the entire circumference of a new piston seal.





(b) Install the piston seal to the disc brake cylinder assembly.

5. INSTALL FRONT DISC BRAKE PISTON

(a) Apply a light layer of lithium soap base glycol grease to the entire circumference of a new cylinder boot.





(b) Install the cylinder boot to the front disc brake piston.

(c) Apply a light layer of lithium soap base glycol grease to the contact surfaces of the front disc brake piston, and install it to the disc brake cylinder assembly.

NOTICE:
Do not install the front disc brake piston forcibly in the disc brake cylinder assembly.

6. INSTALL CYLINDER BOOT

(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 cylinder boot set ring.

NOTICE:
* Install the cylinder boot 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 FRONT DISC BRAKE BUSHING DUST BOOT

(a) Secure the front disc brake cylinder mounting in a vise.

(b) Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new front disc brake bushing dust boots.





HINT
Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol grease to each front disc brake bushing dust boot.

(c) Using a socket wrench (19 mm) and a hammer, install the 2 front disc brake bushing dust boots to the front disc brake cylinder mounting.





8. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSHING

(a) Apply a light layer of lithium soap base glycol grease to the contact surface of the No. 2 front disc brake cylinder slide pin.





(b) Install a new front disc brake cylinder slide bushing to the No. 2 front disc brake cylinder slide pin.

9. INSTALL NO. 2 FRONT DISC BRAKE CYLINDER SLIDE PIN

(a) Apply a light layer of lithium soap base glycol grease to the sliding and sealing surfaces 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 front disc brake cylinder mounting.





10. INSTALL NO. 1 FRONT DISC BRAKE CYLINDER SLIDE PIN

(a) Apply a light layer of lithium soap base glycol grease to the sliding and sealing surfaces of the No. 1 front disc brake cylinder slide pin.





(b) Install the No. 1 front disc brake cylinder slide pin to the front disc brake cylinder mounting.





11. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING

(a) Install the front disc brake cylinder mounting to the steering knuckle with the 2 bolts.





Torque : 107 Nm (1,090 kgf-cm, 79 ft-lbf)

12. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE

(a) Install the front disc brake pad support plate to the front disc brake cylinder mounting.

13. INSTALL FRONT ANTI-SQUEAL SHIM

(a) Apply disc brake grease to each front anti-squeal shim.





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

(b) Install the 2 front anti-squeal shims and the 2 pad wear indicators to each pad.

NOTICE:
Install the shims in the correct positions and directions.





NOTICE:
Install the pad wear indicator in the correct positions and directions.

14. INSTALL FRONT BRAKE PAD

(a) Install the 2 front brake pads with the front anti-squeal shims to the front disc brake cylinder mounting.

(b) Install the 2 anti-squeal springs.