Removal And Installation

FRONT DISC BRAKE

Removal and Installation of Brake Caliper and Rotor


WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne particles or other materials.

CAUTION:
- When removing and installing the cylinder body, do not depress the brake pedal because the piston will pop out.
- Do not damage the piston boot.
- Keep the brake rotor free from grease and brake fluid.
- Refill the brake reservoir with new brake fluid only.
- Never reuse the drained brake fluid.
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.

REMOVAL

1.Remove front wheel and tire.
2.Secure the disc rotor using a wheel nut.
3.Remove the reservoir cap.





4.Remove the union bolt (1) and then disconnect the brake hose from the caliper assembly. Discard the copper sealing washers.

CAUTION:
Do not reuse copper sealing washers.
5.Remove the torque member bolts (2), and remove the brake caliper assembly.

CAUTION:
Do not drop the brake pads.





6.Remove the disc rotor. If reusing the disc rotor, apply a matching mark as shown for installation.

CAUTION:
Put matching marks on wheel hub assembly and disc rotor, if reusing the disc rotor.

INSTALLATION






1.Install the disc rotor. If reusing the disc rotor, align the matching mark on the disc rotor and wheel hub assembly for installation as shown.

CAUTION:
Align the matching marks on wheel hub assembly and disc rotor, if reusing the disc rotor.
2.Install the brake caliper assembly, and tighten the torque member bolts to the specified torque.

CAUTION:
Do not allow oil or any moisture on all contact surfaces between steering knuckle and caliper assembly, bolts, and washer.





3.Install the brake hose with two new copper sealing washers (1), using the L-shaped pin for alignment as shown, then tighten the union bolt (A) to the specified torque.

CAUTION:
Do not reuse copper sealing washers.
4.Refill the brake hydraulic system with new brake fluid and bleed brake system. Service and Repair.
5.Check the front disc brakes for drag.
6.Install the front wheel and tire. Adjustment.