Removal and Replacement

FRONT BRAKE

COMPONENTS:

REMOVAL
1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces.





3. DISCONNECT FRONT FLEXIBLE HOSE
(a) Remove the union bolt and gasket and separate the flexible hose from the disc brake cylinder.





4. REMOVE DISC BRAKE CYLINDER ASSEMBLY
(a) Fix the slide pin with a spanner, remove the 2 bolts and remove the disc brake cylinder.





5. REMOVE FRONT DISC BRAKE PAD KIT (PAD ONLY)
(a) Remove the 2 disc brake pads from the disc brake cylinder mounting.

6. REMOVE FRONT ANTI SQUEAL SHIM KIT
(a) Remove the No. 1 anti squeal shim and No. 2 anti squeal shim from each brake pad.

7. REMOVE NO. 1 PAD WEAR INDICATOR PLATE
(a) Remove the indicator plate from each brake pad.





8. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Remove the 4 disc brake pad support plates from the disc brake cylinder mounting.





9. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Remove the slide pin (upper) and slide pin (lower) from the disc brake cylinder mounting.





10. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH
(a) Using a screwdriver with its tip wrapped in protective tape, remove the slide bush from the slide pin (lower).





11. REMOVE NO. 1 BUSH DUST BOOT
(a) Remove the 2 dust boots from the disc brake cylinder mounting.





12. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING
(a) Remove the 2 bolts and remove the disc brake cylinder mounting from the steering knuckle.





13. REMOVE FRONT DISC
(a) Place matchmarks on the disc and axle hub and remove the disc.

INSTALLATION





1. INSTALL FRONT DISC
(a) Align the matchmarks of the disc and axle hub and install the disc.

NOTICE: When replacing the disc, select the position that gives the minimum disc runout.





2. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING
(a) Install the disc brake cylinder mounting onto the steering knuckle with the 2 bolts.
Torque: 107 N*m (1,089 kgf*cm, 79 ft.*lbf)





3. INSTALL NO. 1 BUSH DUST BOOT
(a) Apply lithium soap base glycol grease to 2 new dust boots.
(b) Install the 2 dust boots onto the disc brake cylinder mounting.





4. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH
(a) Apply lithium soap base glycol grease to the slide pins and a new slide bush, as shown in the illustration.
(b) Install the slide bush onto the slide pin (lower).





5. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Install the slide pin (upper) and slide pin (lower) onto the cylinder mounting.





6. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the 4 disc brake pad support plates onto the disc brake cylinder mounting.

7. INSTALL NO. 1 PAD WEAR INDICATOR PLATE
(a) Install the indicator plates onto the upper side of the brake pad.





8. INSTALL FRONT ANTI SQUEAL SHIM KIT
(a) Apply disc brake grease to both sides of each No. 1 anti-squeal shim.
(b) Install the anti squeal shims onto each brake pad.





9. INSTALL FRONT DISC BRAKE PAD KIT (PAD ONLY)
(a) Install the 2 disc brake pads onto the disc brake cylinder mounting.

NOTICE: There should be no oil or grease on the friction surfaces of the disc brake pads or the front disc.





10. INSTALL DISC BRAKE CYLINDER ASSEMBLY
(a) Install the disc brake cylinder onto the disc brake cylinder mounting with the 2 bolts.
Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf)





11. CONNECT FRONT FLEXIBLE HOSE
(a) Connect the flexible hose with the union bolt and a new gasket.
Torque: 30 N*m (310 kgf*cm, 22 ft.*lbf)

HINT: Install the flexible hose lock securely into the lock hole in the disc brake cylinder.

12. FILL RESERVOIR WITH BRAKE FLUID
13. BLEED MASTER CYLINDER
14. BLEED BRAKE LINE
15. CHECK FLUID LEVEL IN RESERVOIR
16. CHECK FOR BRAKE FLUID LEAKAGE
17. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)