Front brake
Components Removal / installation
FRONT BRAKE
FRONT BRAKE
EXPLODED VIEW
REMOVAL
NOTE:
·The following procedure is for LH side.
·Service the LH side and the RH side using the same procedure.
·Service the LH side and the RH side using the same procedure.
1. Removal of front tire
2. Draining of brake fluid
CAUTION:
Do not let brake fluid come into contact with the painted surface. If it happens, wash it out immediately.
3. Disconnection of front flexible hose No.1
(1) Remove a union bolt and 2 gaskets to disconnect the front flexible hose No.1 from the front disk brake cylinder ASSY LH.
4. Removal of front disc brake cylinder ASSY LH
(1) Remove 2 bolts and then remove the front disc brake cylinder ASSY LH.
5. Removal of front disc brake pad (15 inch type)
6. Removal of front disc brake pad (16 inch type)
7. Removal of spring (L)
(1) Remove the spring (L) from the front disc brake cylinder mounting LH.
8. Removal of spring (pad)
(1) Remove the spring (pad) from the front disc brake cylinder mounting LH.
9. Removal of front disc brake cylinder slide pin
(1) Remove the front disc brake cylinder slide pin from the front disc brake cylinder mounting LH.
10. Removal of front disc brake cylinder slide pin No.2
(1) Remove the front disc brake cylinder slide pin No.2 from the front disc brake cylinder mounting LH.
11. Removal of boot (pin)
(1) Remove the boot (pin) from the front disc brake cylinder mounting LH.
12. Removal of bushing
13. Removal of front disc brake cylinder mounting LH
(1) Remove 2 bolts and then the front disc brake cylinder mounting LH.
DISASSEMBLY
1. Removal of cylinder boot
2. Removal of front disc brake piston
(1) Put a wooden block between the pistons of the cylinder ASSY to prevent the pistons from popping out.
Captions in illustration
| *1 |
Wooden block |
| *a |
30mm {1.181in} |
(2) Using an air gun, gradually blow air into the applicable part to remove the 2 front disc brake pistons from the cylinder.
WARNING:
Be careful not to pinch your fingers.
CAUTION:
Be careful not to spill brake fluid.
NOTE:
Replace the front disc brake cylinder ASSY, if the front disc brake piston is damaged.
(3) Remove the wooden block.
3. Removal of piston seal
4. Removal of front disc brake bleeder plug cap
(1) Remove the front disc brake bleeder plug cap from the front disc brake bleeder plug.
5. Removal of front disc brake bleeder plug
(1) Remove the front disc brake bleeder plug.
INSPECTION
1. Disc brake piston and cylinder check
(1) Check that there is no damage on the side of the disc brake piston and the cylinder wall.
2. Disc brake pad thickness check
Limit
: 1.5mm {0.059in}
Reference value
: 11.0mm {0.433in} (New)
3. Front disc thickness check
Limit
: 22.0mm {0.866in}
Reference value
: 24.0mm {0.945in} (New)
4. Disc runout check
(1) Before checking the disc runout, check the hub & bearing ASSY play (Refer to 
) and runout (Refer to ).
) and runout (Refer to ).(2) Install the front disc to the axle hub and secure it with 5 hub nuts.
Standard value:
Standard value:
Tightening torque=120N·m
{
1224kgf·cm}
{88.5ft·lbf}
(3) Using a dial gauge, check the runout 10 mm{0.394 in} inside of the disc outer periphery.
Limit
: 0.05mm {0.002in}
Captions in illustration
| *1 |
Dial gauge |
CAUTION:
·Do not bring the magnetized part of the dial gauge close to the axle hub or speed sensor.
·Install the dial gauge to the shock absorber.
·When the runout exceeds the limit, change the disc and axle positions to minimize the runout and install them. If the runout still exceeds the limit even after changing the positions, replace the disc with a new one.
·Install the dial gauge to the shock absorber.
·When the runout exceeds the limit, change the disc and axle positions to minimize the runout and install them. If the runout still exceeds the limit even after changing the positions, replace the disc with a new one.
ASSEMBLY
1. Temporarily tightening of front disc brake bleeder plug
(1) Temporarily tighten the front disc brake bleeder plug to the front disc brake cylinder ASSY LH.
2. Installation of front disc brake bleeder plug cap
(1) Install the front disc brake bleeder plug cap to the front disc brake bleeder plug.
3. Installation of piston seal
4. Installation of front disc brake piston
(1) Apply rubber grease (RENOLIT rubber grease JP) or equivalent to a new cylinder boot.
Captions in illustration
| *1 |
Cylinder boot |
| *2 |
Front disc brake piston |
 |
Rubber grease (RENOLIT rubber grease JP) or equivalent |
(2) Securely install the cylinder boot to the front disc brake piston groove.
(3) Apply a thin coat of rubber grease (RENOLIT rubber grease JP) or equivalent to the outer peripheries of 2 front disc brake pistons, and install them to the front disc brake cylinder ASSY LH.
CAUTION:
Do not push the front disc brake piston in with excessive force.
INSTALLATION
NOTE:
·The following procedure is for LH side.
·Service the LH side and the RH side using the same procedure.
·Service the LH side and the RH side using the same procedure.
1. Installation of front disc
(1) When removing/installing the front disc
(a) Aligning the mark which you put at the time of removal, install the front disc to the axle hub.
(2) When replacing the front disc
(a) Check the disc runout (Refer to ) and install the front disc to the axle hub.
) and install the front disc to the axle hub.(3) Temporarily tighten the hub nut to secure the front disc to the axle hub.
2. Installation of front disc brake cylinder mounting LH
(1) Install the carriers with new 2 bolts.
Standard value:
Standard value:
Tightening torque=80N·m
{
816kgf·cm}
{59.0ft·lbf}
3. Installation of boots (pins)
(1) Apply rubber grease all around the engaging parts of new 2 boots (pins).
Captions in illustration
|
|
Application area for rubber grease (NIGLUBE RX-2) or equivalent |
NOTE:
Apply 1.5±2.0 g of rubber grease (NIGLUBE RX-2) or equivalent per 1 front disc brake bushing dust boot.
(2) Install 2 front disc brake bushing dust boots to the front disc brake cylinder mounting LH.
4. Installation of bushing
(1) Apply a thin coat of rubber grease (NIGLUBE RX-2) or equivalent all around the contacting surface of the new bushing and the front disc brake cylinder slide pin No.2.
Captions in illustration
|
|
Application area for rubber grease (NIGLUBE RX-2) or equivalent |
(2) Install the bushing to the front disc brake cylinder slide pin No.2.
5. Installation of front disc brake cylinder slide pin No.2
Captions in illustration
|
|
Application area for rubber grease (NIGLUBE RX-2) or equivalent |
(1) Apply a thin coat of rubber grease (NIGLUBE RX-2) or equivalent all around the engaging part and the sliding part of the front disc brake cylinder slide pin No.2.
(2) Install the front disc brake cylinder slide pin No.2 to the carrier.
6. Installation of front disc brake cylinder slide pin
Captions in illustration
|
|
Application area for rubber grease (NIGLUBE RX-2) or equivalent |
(1) Apply a thin coat of rubber grease (NIGLUBE RX-2) or equivalent all around the engaging part and the sliding part of the front disc brake cylinder slide pin.
(2) Install the front disc brake cylinder slide pin to the carrier.
7. Installation of spring (L)
8. Installation of spring (pad)
NOTE:
Service the spring (pad) in the same procedures for the spring (L).
9. Installation of front disc brake pad (15 inch type)
10. Installation of front disc brake pad (16 inch type)
11. Installation of front disc brake cylinder ASSY LH
(1) Install the front disc brake cylinder ASSY LH to the carrier with 2 bolts.
Standard value:
Standard value:
Tightening torque=26N·m
{
270kgf·cm}
{19.2ft·lbf}
12. Connection of front flexible hose No.1
(1) Using a new union bolt, connect the front flexible hose No.1 to the disc brake cylinder ASSY via 2 new gaskets.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
13. Brake fluid refill (Refer to )
)14. Air bleeding of brake system (Refer to )
)15. Brake fluid leak check
16. Brake fluid level check (Refer to )
)17. Installation of front tire
Standard value:
Standard value:
Tightening torque=120N·m
{
1224kgf·cm}
{88.5ft·lbf}