Front

FRONT BRAKE

DISASSEMBLY





1. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
(a) Hold the cylinder mounting LH in a vise between aluminum plates.
(b) Using a screwdriver and hammer, remove the 2 bush dust boots from the cylinder mounting LH.

NOTICE: Do not damage the cylinder mounting LH.





2. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the set ring and cylinder boot.

NOTICE: Do not damage the piston groove or cylinder groove.

HINT: Tape the screwdriver tip before use.





3. REMOVE FRONT DISC BRAKE PISTON
(a) Place a shop rag or a piece of cloth between the disc brake piston and the disc brake cylinder assembly.
(b) Use compressed air to remove the disc brake piston from the disc brake cylinder assembly.

CAUTION: Do not place your fingers in front of the piston when using compressed air.

NOTICE: Do not spatter the brake fluid.





4. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal from the disc brake cylinder assembly.

NOTICE: Do not damage the inner cylinder or cylinder groove.

HINT: Tape the screwdriver tip before use.

5. REMOVE FRONT DISC BRAKE BLEEDER PLUG
6. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP

REASSEMBLY
1. INSTALL FRONT DISC BRAKE BLEEDER PLUG
2. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
3. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder assembly.





4. INSTALL FRONT DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the disc brake piston and new cylinder boot.
(b) Install the cylinder boot to the disc brake piston.
(c) Install the disc brake piston to the disc brake cylinder assembly.

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





5. INSTALL CYLINDER BOOT
(a) Install the cylinder boot to the disc brake cylinder assembly.

NOTICE: Install the cylinder boot securely into the grooves of the cylinder and piston.

(b) Using a screwdriver, install the set ring.

NOTICE:
^ Install the set ring securely into the grooves of the cylinder boot.
^ Do not damage the cylinder boot.

HINT: Tape the screwdriver tip before use.





6. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Secure the cylinder mounting LH in a vise.
(b) Apply lithium soap base glycol grease to the sealing surface of 2 new bush dust boots.
(c) Using a socket wrench (19 mm) and hammer, install the 2 bush dust boots to the cylinder mounting LH.

7. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH
(a) Apply lithium soap base glycol grease to a new cylinder slide bush.
(b) Install the cylinder slide bush to the cylinder slide pin (No.2).