BRAKE ACTUATOR INSTALLATION

PROCEDURE


  1. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET


    1. A004PS1E01

      Install the brake actuator with bracket with the 3 nuts. Tighten the 3 nuts uniformly in alphabetical order.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

      Note


      • Be careful not to damage the brake tubes and wire harness.

      • Do not drop the actuator. If dropped, replace it.

    2. Install 2 new tube clamps to the tubes, and then attach the 2 clamps to the brake actuator bracket.

  2. CONNECT BRAKE LINE


    1. A004MU9E01
      Text in Illustration
      *a To Front Wheel Cylinder RH
      *b To Front Wheel Cylinder LH
      *c To Rear Wheel Cylinder RH
      *d To Rear Wheel Cylinder LH
      *e From Master Cylinder

      Set each brake line in the correct position on the brake actuator as shown in the illustration.

    2. A004N89E02
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using a union nut wrench, connect the 6 brake lines to the brake actuator.

      Torque:
      for flare nut A
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      for flare nut B
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • for flare nut A

        When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13 N*m (137 kgf*cm, 10 ft.*lbf).

      • for flare nut B

        When using a union nut wrench (fulcrum length of 20 mm (0.7874 in.)) + torque wrench (fulcrum length of 180 mm (7.0866 in.)): 18 N*m (179 kgf*cm, 13 ft.*lbf).

  3. CONNECT CONNECTOR


    1. A004TGL

      Connect the connector to the brake actuator assembly and lock the lock lever.

      Text in Illustration
      A004P4E Lock Lever Locked

  4. INSTALL BRAKE ACTUATOR COVER (for 1WW, 2WW)


    1. Install a new brake actuator cover to the brake actuator assembly.

  5. INSTALL FUEL FILTER ELEMENT ASSEMBLY


    1. for 1WW:

      Install the fuel filter element assembly Click here.

    2. for 2WW:

      Install the fuel filter element assembly Click here.

  6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  7. REMOVE CENTER COWL TOP VENTILATOR LOUVER

    Click here

  8. FILL RESERVOIR WITH BRAKE FLUID

    Click here

  9. BLEED AIR FROM BRAKE MASTER CYLINDER

    Click here

  10. BLEED AIR FROM BRAKE LINE

    Click here

  11. CHECK BRAKE FLUID LEVEL IN RESERVOIR

    Click here

  12. INSPECT FOR BRAKE FLUID LEAK

  13. INSTALL CENTER COWL TOP VENTILATOR LOUVER

    Click here

  14. CHECK BRAKE ACTUATOR ASSEMBLY WITH GTS


    1. Check the brake actuator with the GTS Click here.