FRONT BRAKE INSTALLATION


  1. INSTALL FRONT DISC

    (See Pub. No. RM1008E, page 30-45)

  2. INSTALL FRONT AXLE HUB SUB-ASSEMBLY

    (See Pub. No. RM1008E, page 30-45)

  3. INSTALL FRONT AXLE HUB OUTER BEARING

    (See Pub. No. RM1008E, page 30-45)

  4. INSPECT DISC RUNOUT


    1. A01CJE0

      Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the disc.

      Maximum disc runout
      0.1 mm (0.0039 in.)

      Tech Tips

      If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maximum even when the installation positions are changed, check the bearing play in the axial direction and the axle hub runout. If the bearing play and the axle hub runout are normal and if the disc thickness is not within the specified range, shave the disc. If the disc thickness is less than the minimum, replace the disc.

  5. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING


    1. A01CIGB

      Install the front disc brake cylinder mounting with the 3 bolts.

      Torque:
      265 N*m  { 2700 kgf*cm, 195 ft.*lbf }

  6. INSTALL NO. 1 BUSHING DUST BOOT


    1. Apply lithium soap base glycol grease to the seal surface of a new No. 1 bushing dust boot. Click here

    2. Install the No. 1 bushing dust boot to the front disc brake cylinder mounting.

  7. INSTALL NO. 2 BUSHING DUST BOOT

    Tech Tips

    Install the No. 2 bushing dust boot using the same procedure as for the No. 1 bushing dust boot.

  8. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN


    1. Apply lithium soap base glycol grease to the sliding part and the seal surface of the front disc brake cylinder slide main pin. Click here

    2. A01CHL8E01

      Install the cylinder slide pin No. 1 to the front disc brake cylinder mounting as shown in the illustration.

  9. INSTALL NO. 1 FRONT DISC BRAKE PAD SUPPORT PLATE


    1. Install the 2 No. 1 front disc brake pad support plates to the front disc brake cylinder mounting.

  10. INSTALL NO. 2 FRONT DISC BRAKE PAD SUPPORT PLATE


    1. Install the 2 No. 2 front disc brake pad support plates to the front disc brake cylinder mounting.

  11. INSTALL FRONT DISC BRAKE ANTI-SQUEAL SHIM

    Note

    When replacing worn pads, the anti-squeal shims must be replaced together with the pads.


    1. A01CGNZE01

      Install the 2 No. 2 anti-squeal shims and 2 No. 1 anti-squeal shims to each pad.

  12. INSTALL FRONT DISC BRAKE PAD


    1. Install the 2 brake pads to the front disc brake cylinder mounting.

  13. INSTALL DISC BRAKE CYLINDER ASSEMBLY


    1. A01CHB4

      Install the disc brake cylinder assembly with the 2 bolts.

      Torque:
      125 N*m  { 1270 kgf*cm, 92 ft.*lbf }

    2. Connect the flexible hose with the union bolt and 2 new gaskets.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }

  14. FILL RESERVOIR WITH BRAKE FLUID

    (See Pub. No. RM1008E, page 32-4)

  15. BLEED BRAKE LINE

    (See Pub. No. RM1008E, page 32-4)

  16. CHECK FLUID LEVEL IN RESERVOIR

    (See Pub. No. RM1008E, page 32-4)

  17. INSPECT FOR BRAKE FLUID LEAK

    (See Pub. No. RM1008E, page 32-4)

  18. INSTALL FRONT WHEEL

    Torque:
    515 N*m  { 5250 kgf*cm, 380 ft.*lbf }