FRONT BRAKE REASSEMBLY

Tech Tips


  • Use the same procedures for the LH side and RH side.

  • The procedures listed below are for the LH side.


  1. INSTALL FRONT DISC

    A01J5XDE01

    1. 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 minimum runout.

  2. CHECK DISC RUNOUT

    A01J471

    1. Check the bearing play in the axial direction and check the axle hub runout Click here.

    2. Temporarily install the disc to the hub with the hub nuts.

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

      Maximum disc runout
      0.05 mm (0.0020 in.)

      If the runout is greater than the maximum, change the installation positions of the disc and axle so that the runout will become minimal.

      If the runout is greater than the maximum even when the installation positions are changed, grind the disc.

      If the disc thickness is less than the minimum, replace the disc.

    4. Remove the 6 nuts.

  3. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG


    1. Install the bleeder plug to the cylinder.

      Tech Tips

      The bleeder plug will be tightened to a torque specification in the "BLEED AIR FROM BRAKE LINE" procedures.

    2. Install the cap to the bleeder plug.

  4. INSTALL PISTON SEAL


    1. Apply lithium soap base glycol grease to 4 new seals.

    2. Install the 4 seals to the cylinder.

      Note

      Do not forcibly install the seals to the cylinder.

  5. INSTALL FRONT DISC BRAKE PISTON

    A01J35UE01

    1. Apply lithium soap base glycol grease to the 4 pistons and 4 new cylinder boots.

    2. Install the 4 boots to the pistons.

    3. Install the 4 pistons (with the boots) to the cylinder.

      Note

      Do not forcibly install the pistons to the cylinder.

  6. INSTALL CYLINDER BOOT

    A01J5OD

    1. Install the boots into the grooves of the cylinder and pistons.

      Note

      Make sure that the boots are securely installed into the grooves of the cylinder and pistons.

    2. Using a screwdriver, install the 4 set rings.

      Note

      Be careful not to damage the boot.