INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL FRONT DISC

(a) Align the matchmarks and install the front disc.

NOTICE:

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

2. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING

(a) Install the front disc brake cylinder mounting to the steering knuckle with the 2 bolts.

Torque:

104 N·m {1061 kgf·cm, 77 ft·lbf}

3. INSTALL FRONT DISC BRAKE BUSH DUST BOOT

(a) Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new front disc brake bush dust boots. Text in Illustration *1 Lithium soap base glycol grease

(b) Install the 2 front disc brake bush dust boots to the front disc brake cylinder mounting.

4. INSTALL NO. 1 FRONT DISC BRAKE CYLINDER SLIDE PIN

(a) Apply a light layer of lithium soap base glycol grease to the sliding part and the seal surface of the No. 1 front disc brake cylinder slide pin. Text in Illustration *1 Lithium soap base glycol grease

(b) Install the No. 1 front disc brake cylinder slide pin to the front disc brake cylinder mounting.

(c) Push the No. 1 front disc brake cylinder slide pin into the front disc brake bush dust boot to align them.

5. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH

(a) Apply a light layer of lithium soap base glycol grease to the contact surface of the No. 2 front disc brake cylinder slide pin. Text in Illustration *1 Lithium soap base glycol grease

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

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

(a) Apply a light layer of lithium soap base glycol grease to the sliding part and the seal surface of the No. 2 front disc brake cylinder slide pin. Text in Illustration *1 Lithium soap base glycol grease

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

(c) Push the No. 2 front disc brake cylinder slide pin into the front disc brake bush dust boot to align them.

7. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE

(a) Install the 4 front disc brake pad support plates to the front disc brake cylinder mounting as shown in the illustration. Text in Illustration *1 No. 1 Front Disc Brake Pad Support Plate *2 No. 2 Front Disc Brake Pad Support Plate *3 No. 3 Front Disc Brake Pad Support Plate *4 No. 4 Front Disc Brake Pad Support Plate NOTICE: Be sure to install each front disc brake pad support plate to the correct position and direction. HINT: The front disc brake pad support plate (lower) has a convex part.

8. INSTALL PAD WEAR INDICATOR PLATE

(a) Install the 2 pad wear indicator plates to the pads. NOTICE: Install the pad wear indicator plates in the correct positions and directions.

9. INSTALL FRONT ANTI-SQUEAL SHIM

(a) Apply disc brake grease to the inside of the 2 front anti-squeal shims as shown in the illustration. Text in Illustration *1 Disc brake grease NOTICE: When replacing worn pads, the front anti-squeal shims must be replaced together with the pads. Apply disc brake grease to the area that contacts the front anti-squeal shims. Disc brake grease can come out slightly from the area where the front anti-squeal shims are installed. Make sure that disc brake grease is not applied onto the lining surface.

(b) Install the 2 front anti-squeal shims to the front disc brake pads. NOTICE: Install the front anti-squeal shims in the correct positions and directions.

10. INSTALL FRONT DISC BRAKE PAD

(a) Install the 2 front disc brake pads with the front anti-squeal shims to the front disc brake cylinder mounting.

(b) Install the 2 anti-squeal springs to the front disc brake pads. NOTICE: When replacing the front disc brake pads with new ones, make sure to replace the anti-squeal springs at the same time. Be sure to install the anti-squeal springs into the front disc brake pad installation holes as far as they will go.

11. INSTALL DISC BRAKE CYLINDER ASSEMBLY

(a) Hold the 2 front disc brake cylinder slide pins and install the disc brake cylinder assembly with the 2 bolts.

Torque:

34 N·m {350 kgf·cm, 25 ft·lbf}

12. CONNECT FRONT FLEXIBLE HOSE

(a) Connect the front flexible hose to the disc brake cylinder assembly with a new gasket and a new union bolt.

Torque:

29 N·m {300 kgf·cm, 22 ft·lbf}

NOTICE:

Install the front flexible hose lock securely in the lock hole in the disc brake cylinder assembly.

13. FILL RESERVOIR WITH BRAKE FLUID

14. BLEED BRAKE LINE

15. INSPECT FOR BRAKE FLUID LEAK

16. INSPECT FLUID LEVEL IN RESERVOIR

17. INSTALL FRONT WHEEL

Torque:

103 N·m {1050 kgf·cm, 76 ft·lbf}