FRONT BRAKE(for 17 inch Front Disc Brake) INSTALLATION

CAUTION / NOTICE / HINT

Tip:

  • Use the same procedure for the RH and LH sides.

  • The procedures listed below are for the LH side.

PROCEDURE

  1. INSTALL FRONT DISC

    1. C278598C02

      *a

      Matchmark

      Align the matchmarks and install the disc.

      Tip:

      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. C193393C01

      *1

      Lithium soap base glycol grease

      Apply a light coat of lithium soap base glycol grease to the entire circumference of 2 new front disc brake bushing dust boots as shown in the illustration.

      Tip:

      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 front disc brake bushing dust boots to the front disc brake cylinder mounting.

  3. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH

    1. C187987C02

      *1

      Lithium soap base glycol grease

      Apply a light coat of lithium soap base glycol grease to the contact surface of a new front disc brake cylinder slide bushing and the No. 2 front disc brake cylinder slide pin.

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

  4. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN

    1. C217115C01

      *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 front disc brake cylinder slide pins as shown in the illustration.

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

    3. Push the front disc brake cylinder slide pin into the front disc brake bushing dust boot to align them.

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

    1. Apply a light coat of lithium soap base glycol grease to the sliding part and the seal surface of the No. 2 front disc brake cylinder slide pin.

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

    3. Push the No. 2 front disc brake cylinder slide pin into the front disc brake bushing dust boot to align them.

  6. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH

    1. Install the cylinder mounting with the 2 bolts.

      106.8 N*m

      1089 kgf*cm

      79 ft.*lbf

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

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

  9. INSTALL NO. 3 FRONT DISC BRAKE PAD SUPPORT PLATE

    1. Install the No. 3 front disc brake pad support plates to the disc brake cylinder mounting.

  10. INSTALL NO. 4 FRONT DISC BRAKE PAD SUPPORT PLATE

    1. Install the No. 4 front disc brake pad support plates to the disc brake cylinder mounting.

  11. INSTALL NO. 1 PAD WEAR INDICATOR PLATE

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

  12. INSTALL FRONT ANTI-SQUEAL SHIM KIT

    1. C279246C01

      *1

      Front Disc Brake Pad

      *2

      No. 1 Front Anti-squeal Shim

      *3

      No. 2 Front Anti-squeal Shim

      Apply disc brake grease between the front disc brake pads.

    2. Install the 2 No.1 anti-squeal shims and No. 2 anti-squeal shims to the front disc brake 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.

  13. INSTALL FRONT DISC BRAKE PAD

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

      Note:

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

  14. INSTALL DISC BRAKE CYLINDER ASSEMBLY LH

    1. C279250C01

      *a

      Hold

      *b

      Turn

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

      34.3 N*m

      350 kgf*cm

      25 ft.*lbf

  15. CONNECT FRONT FLEXIBLE HOSE

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

      29.4 N*m

      300 kgf*cm

      22 ft.*lbf

      Tip:

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

  16. REMOVE COWL TOP VENTILATOR LOUVER BRACKET LH

    Click here

  17. BLEED BRAKE LINE

    Click here

  18. INSTALL COWL TOP VENTILATOR LOUVER BRACKET LH

    Click here

  19. INSTALL FRONT WHEEL

    103 N*m

    1050 kgf*cm

    76 ft.*lbf