Front Disc Brake

FRONT DISC BRAKE

Disassembly and Assembly











NOTE:
Do not remove the torque member, pads, shims, shim covers, and anti-rattle clips when disassembling and assembling the cylinder body.

DISASSEMBLY

1.Remove the sliding pin bolts, and then remove the cylinder body from the torque member.

CAUTION:
Do not drop pads, shims, shim cover and anti-rattle clips from torque member.
2.Remove the sliding pins, bushing and sliding pin boots from the torque member.
3.Remove the cap and the bleed valve from the cylinder body.





4.Place a wooden block in the cylinder body and blow air through the union bolt hole to push out the piston and piston boot as shown. Discard the piston boot.

WARNING:
Do not get fingers caught between the piston and cylinder body.

CAUTION:
Do not reuse the piston boot.





5.Remove the piston seal from the cylinder body using a suitable tool as shown. Discard the piston seal.

CAUTION:
- Be careful not to damage the inner cylinder wall.
- Do not reuse the piston seal.

INSPECTION AFTER DISASSEMBLY

Cylinder Body
Check the inner cylinder wall for corrosion, wear, and damage. If a defect is detected, replace the cylinder body.

CAUTION:
Clean the cylinder body using new brake fluid. Never use mineral oils such as gasoline or kerosene.
Torque Member
Check the torque member for wear, cracks, and damage. If a defect is detected, replace the torque member.
Piston
Check the piston surface for corrosion, wear, and damage. If a defect is detected, replace the piston.

CAUTION:
The piston sliding surface is plated. Do not polish the piston with sandpaper.
Sliding Pin, Sliding Pin Bolt, and Sliding Pin Boot
Check the sliding pin, sliding pin bolt, and sliding pin boot for wear, damage, and cracks. If a defect is detected, replace the components as necessary.

ASSEMBLY






1.Apply rubber grease to the new piston seal, and install it in the cylinder body.

CAUTION:
Do not reuse piston seal.





2.Apply rubber grease to new piston boot and apply brake fluid to the piston. Cover the piston end with the piston boot, and then install the cylinder side lip on the piston boot securely into a groove on the cylinder body.

CAUTION:
Do not reuse piston boot.





3.Push the piston into the cylinder body by hand and push the piston boot piston-side lip into the piston groove.

CAUTION:
Press the piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed.
4.Install the bleed valve and cap to the cylinder body.
5.Install the sliding pins, bushing and sliding pin boots on the torque member.
6.Install the cylinder body to the torque member, and then tighten the sliding pin bolts to the specified torque.