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Removal and Installation
 
 
REMOVAL
warningClean dust on brake caliper and brake pad with a vacuum dust collector tominimize the hazard of airborne particles or other materials.
caution
  • Do not depress the brake pedal.
  • Do not spill or splash brake fluid on painted areas; it may cause paintdamage. If brake fluid is splashed on painted areas, wash it awaywith water immediately.
  • Do not bend, twist or pull the brake hoses and piping.
  • Do not reuse drained brake fluid.
noteWhen removing components such as hoses, tubes/lines, etc., cap orplug openings to prevent fluid from spilling.
 
 
1. Remove reservoir cap from the reservoir tank.
2. Remove front wheels and tires using power tool.
3. Secure the disc brake rotor using wheel nuts.
4. Remove union bolt, copper sealing washers, and disconnect brake hose from brakecaliper. Discard the copper sealing washers.
cautionDo not reuse copper sealing washers.
5. Remove slide pin bolts and the brake caliper.
cautionDo not drop brake pads or caliper.
6. Remove the brake pads from the torque member.
caution
  • Do not damage the piston boot.
  • Do not drop the brake pads, shims, or the shim covers.
  • Note the position of components during removal to aid withinstallation.
 
 
INSTALLATION
 
 
1. Install the brake pads in the torque member.
caution
  • Do not damage the piston boot.
  • Do not drop the brake pads, shims, or the shim covers.
2. Position the brake caliper to torque member and install the slide pin bolts. Tightento specification.
3. Assemble the union bolt and the copper sealing washers to the brake hoseand install it as an assembly to the brake caliper. Align the brake hose L-pin byaligning it with the brake caliper hole, and tighten the union bolt to the specifiedtorque.
cautionDo not reuse copper sealing washers.
4. Refill with new brake fluid and perform the air bleeding. Refer to Bleeding Brake System.
caution
  • Do not reuse drained brake fluid.
  • Do not spill or splash brake fluid on the disc brake rotor.
5. Install the front wheels and tires. Refer to Removal & Installation.
 
 
INSPECTION AFTER INSTALLATION
 
 
1. Check the drag of front disc brake. If any drag is found, follow the proceduredescribed below.
2. Remove brake pads.
3. Using a suitable tool, press the pistons into the brake caliper body.
cautionDo not damage the piston boots.
4. Install brake pads.
5. Depress the brake pedal several times.
6. Check the drag of front disc brake again. If any drag is found, disassemble thebrake caliper body.
7. Burnish contact surfaces after refinishing or replacing disc brake rotors or if a softpedal occurs at very low mileage. Refer to Inspection and Adjustment.