Installation

BRAKE (FRONT): FRONT BRAKE: INSTALLATION

1. INSTALL FRONT DISC

(a) Align the matchmarks of the disc and axle hub, and install the front disc.





NOTICE:
When replacing the disc with a new one, select the installation position where the front disc has minimal runout.

2. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY

(a) Install the front disc brake cylinder assembly with the 2 bolts.





Torque : 78 Nm (795 kgf-cm, 58 ft-lbf)

3. INSTALL FRONT DISC BRAKE ANTI-SQUEAL SHIM

(a) Apply disc brake grease to the front disc brake anti-squeal shims and front disc brake pads as shown in the illustration.





NOTICE:
When applying the disc brake grease, use the grease enclosed with a front disc brake pad kit or supplied grease (Part No. 90998-94072) or equivalent.

(b) Install the front disc brake anti-squeal shims to each brake pad.

NOTICE:
* Apply grease to the area that contacts the anti-squeal shims.
* When replacing worn pads, the anti-squeal shims must be replaced together with the pads.
* Install the shims in the correct position and direction.
* The grease can seep out slightly from the area where the anti-squeal shim is installed.
* There should be no oil or grease on the friction surfaces of the pads and the disc.

4. INSTALL FRONT DISC BRAKE PAD

NOTICE:
Be sure to inspect the front disc when replacing the brake pads with new ones Front Brake.

(a) Install the front disc brake pads to the front disc brake cylinder assembly.





NOTICE:
* The front brake pad with a pad wear indicator must be installed to the outside position.
* Match the arrow mark on the pad to the forward rotational direction.

(b) Install the pad guide tie rod with the bolt.





Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

(c) Using a pin punch (5 mm) and a hammer, install the pad guide pin (lower) to the front disc brake cylinder assembly.





NOTICE:
* Do not damage the disc brake cylinder surface.
* Securely engage the ring of the pad guide pin to the front disc brake cylinder assembly.

(d) Install the anti-rattle spring to the front disc brake cylinder assembly.





NOTICE:
Securely install the anti-rattle spring in the correct position and direction.

(e) Holding the anti-rattle spring, insert the pad guide pin (upper) to the front disc brake cylinder assembly as shown in the illustration.





(f) Using a pin punch (5 mm) and a hammer, install the pad guide pin (upper) to the front disc brake cylinder assembly.





NOTICE:
* Do not damage the disc brake cylinder surface.
* Securely engage the ring of the pad guide pin to the front disc brake cylinder assembly.

5. CONNECT FRONT FLEXIBLE HOSE

(a) Connect the front flexible hose to the front disc brake cylinder assembly with the union bolt and a new gasket.





Torque : 39 Nm (398 kgf-cm, 29 ft-lbf)

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

6. FILL RESERVOIR WITH BRAKE FLUID Service and Repair

7. BLEED BRAKE LINE Service and Repair

8. INSPECT FOR BRAKE FLUID LEAK

9. INSPECT FLUID LEVEL IN RESERVOIR Testing and Inspection

10. INSTALL FRONT WHEEL

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)