Reassembly

BRAKE: FRONT BRAKE: REASSEMBLY

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

1. INSTALL FRONT DISC
(a) Align the matchmarks on the disc and the axle hub. Install the front disc.
NOTE: When installing a new disc, select the position where the disc has the minimum runout.

2. INSPECT DISC RUNOUT





(a) Check the looseness of the front wheel bearing and runout in the axle hub before inspecting the disc runout Front Axle Hub.
(b) Hold the front disc with the 5 hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft-lbf)
(c) Holding a dial indicator 10 mm (0.394 in.) away from the outer edge of the front disc, measure the disc runout.
Maximum disc runout:
0.05 mm (0.0020 in.)
NOTE: If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds even when the installation positions are changed or if disc thickness does not exceed the limit, shave the disc. If disc thickness exceeds the limit, replace the disc.

(d) Remove the 5 hub nuts.
3. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
4. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
5. INSTALL PISTON SEAL





(a) Apply a light layer of lithium soap base glycol grease to the entire circumference of a new piston seal.
(b) Install the piston seal to the front disc brake cylinder sub-assembly.
NOTE: Securely install the piston seal into the groove of the front disc brake cylinder sub-assembly.

6. INSTALL FRONT DISC BRAKE PISTON
(a) Check the side of the front disc brake piston for any scratch.
NOTE: Replace the front disc brake piston with a new one if there is any scratch on it.





(b) Apply a light layer of lithium soap base glycol grease to the entire circumference of a new cylinder boot.
(c) Install the cylinder boot to the front disc brake piston.
(d) Apply a light layer of lithium soap base glycol grease to the contact surfaces of the front disc brake piston, and install it to the front disc brake cylinder sub-assembly.
NOTICE:
- Do not install the piston forcibly into the front disc brake cylinder sub-assembly.
- Do not damage the piston tip during installation.
- Do not push the piston directly using hard or sharp tools.

7. INSTALL CYLINDER BOOT





(a) Install the cylinder boot to the disc brake cylinder groove.
NOTE: Install the cylinder boot securely into the disc brake cylinder and piston groove.

(b) Using a screwdriver, install a new front disc brake piston set ring to the front disc brake cylinder.
NOTE: Do not damage the cylinder boot.