Disassembly

BRAKE: FRONT BRAKE:

DISASSEMBLY

HINT:
- Use the same procedures for the RH side and LH side.
- The procedures listed below are for the LH side.

1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID

NOTE: Wash brake fluid off immediately if it adheres to any painted surface.

3. DISCONNECT FRONT FLEXIBLE HOSE
(a) Remove the union bolt and the the gasket from the disc brake cylinder sub-assembly, then disconnect the flexible hose.
4. REMOVE FRONT DISC BRAKE CYLINDER SUB-ASSEMBLY





(a) Hold the front disc brake cylinder slide pin (No. 1), side pin (No. 2) and remove the 2 bolts.
5. REMOVE FRONT DISC BRAKE PAD
(a) Remove the 2 front disc brake pads with anti squeal shims from the front disc brake cylinder mounting.
6. REMOVE FRONT ANTI SQUEAL SHIM
(a) Remove the 2 front anti squeal shims from each pad.
(b) Using a screwdriver, remove the pad wear indicator plates from each pad.
7. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Remove the front disc brake pad support plate (No. 1) and front disc brake pad support plate (No. 2) from the front disc brake cylinder mounting.
8. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN





(a) Remove the front disc brake cylinder slide pin (No. 1) and front disc brake cylinder slide pin (No. 2) from the front disc brake cylinder mounting.
9. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSHING





(a) Using a screwdriver, remove the front disc brake cylinder slide bushing from the front disc brake cylinder slide pin (No. 2).

NOTE: Do not damage the front disc brake cylinder slide pin (No. 2).

10. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING





(a) Remove the 2 bolts and front disc brake cylinder mounting.
11. REMOVE FRONT DISC BRAKE BUSHING DUST BOOT
(a) Hold the front disc brake cylinder mounting in the vise through the soft jaws.





(b) Using a screwdriver and hammer, remove the 2 front disc brake bushing dust boots from the front disc brake cylinder mounting.
12. REMOVE CYLINDER BOOT





(a) Using a screwdriver, remove the set ring and cylinder boot.

NOTE: Do not damage the piston groove and cylinder groove.

13. REMOVE FRONT DISC BRAKE PISTON
(a) Place a shop rag, between the front disc brake piston and the disc brake cylinder sub-assembly.





(b) Use compressed air to remove the front disc brake piston from the disc brake cylinder sub-assembly.

CAUTION: Do not place your fingers in front of the piston when using compressed air.

NOTE: Do not spatter the brake fluid.

14. REMOVE PISTON SEAL





(a) Using a screwdriver, remove the piston seal from the front disc brake cylinder sub-assembly.

NOTE: Do not damage the inner cylinder and cylinder groove.

15. REMOVE FRONT DISC BRAKE BLEEDER PLUG
(a) Remove the front disc brake bleeder plug from the front disc brake cylinder sub-assembly.
16. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
(a) Remove the bleeder plug cap from the front disc brake bleeder plug.
17. REMOVE FRONT DISC





(a) Place matchmarks on the front disc and the axle hub.
(b) Remove the front disc.