FRONT BRAKE(for 16 inch Front Brake) INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL FRONT DISC

   
   
   1. 

      *a

      Matchmark

      Align the matchmarks and install the disc.

      Tech Tips

      When replacing the disc with a new one, select the installation position where the disc has the smallest runout.

2. INSTALL FRONT DISC BRAKE BUSH DUST BOOT

   
   
   1. 

      *1	Lithium soap base glycol grease

      Apply a light coat of lithium soap base glycol grease to the entire circumference of a new front disc brake bush dust boot, and the entire inner circumference of both ends.

      Tech Tips

      Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol grease to the front disc brake bush dust boot.

      Note

      Apply a sufficient amount of lithium soap base glycol grease to the entire circumference of the front disc brake bush dust boot and front disc brake cylinder mounting contact surfaces.

   2. Install the 2 boots to the mounting.

3. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH

   
   
   1. 

      *1	Lithium soap base glycol grease

      Apply a light coat of lithium soap base glycol grease to the contact surface of the No. 2 front disc brake cylinder slide pin where it contacts the front disc brake cylinder slide bush.

   2. Install a new front disc brake cylinder slide bush to the No. 2 front disc brake cylinder slide pin.

4. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN

   
   
   1. 

      *1	Front Disc Brake Cylinder Slide Pin
      *2	No. 2 Front Disc Brake Cylinder Slide Pin
      *3	Lithium soap base glycol grease

      Apply a light coat of lithium soap base glycol grease to the sliding part and the seal surface of the 2 front disc brake cylinder slide pins.

   2. Install the front disc brake cylinder slide pin to the mounting.

5. INSTALL NO. 2 FRONT DISC BRAKE CYLINDER SLIDE PIN

   
   

   1. Install the No. 2 front disc brake cylinder slide pin to the mounting.

6. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH

   
   

   1. Install the cylinder mounting with the 2 bolts.

      Torque:

      106.8 N*m  { 1089 kgf*cm, 79 ft.*lbf }

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

   
   

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

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

   
   

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

9. INSTALL NO. 1 PAD WEAR INDICATOR PLATE

   
   

   1. Install the 2 pad wear indicator plates to the pads.

10. INSTALL FRONT ANTI-SQUEAL SHIM KIT

    
    
    1. 

       *1	Front Disc Brake Pad
       *2	No. 1 Anti-squeal Shim
       *3	No. 2 Anti-squeal Shim (Inner)
       *4	No. 2 Anti-squeal Shim (Outer)

       Install the No. 1 and No. 2 shims to the pads.

       Note

       
       

       • When replacing a worn pad, the shims must be replaced together with the pads.

       • Install the shims in the correct positions and direction as shown in the illustration.

11. INSTALL FRONT DISC BRAKE PAD

    
    

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

       Note

       Make sure there is no oil or grease on the friction surfaces of the pads and disc.

12. INSTALL DISC BRAKE CYLINDER ASSEMBLY LH

    
    
    1. 

       *a	Hold
       *b	Turn

       Hold the front disc brake cylinder slide pins and install the disc brake cylinder to the disc brake cylinder mounting with 2 new bolts.

       Torque:

       34.3 N*m  { 350 kgf*cm, 25 ft.*lbf }

13. CONNECT FRONT FLEXIBLE HOSE

    
    

    1. 

       Install a new gasket and connect the flexible hose with a new union bolt.

       Torque:

       29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }

       Tech Tips

       Insert the flexible hose lock securely into the lock hole in the cylinder.

14. REMOVE COWL TOP VENTILATOR LOUVER BRACKET LH

    Click here

15. BLEED BRAKE LINE

    Click here

16. INSTALL COWL TOP VENTILATOR LOUVER BRACKET LH

    Click here

17. INSTALL FRONT WHEEL

    Torque:

    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }