Overhaul

1. Remove the union bolt and gasket from the disc brake cylinder, then disconnect the flexible hose.

2. Hold the cylinder slide pin and remove the 2 bolts.

1. 1
   remove the 2 brake pads with anti–squeal shims.
2. 2
   remove the anti–squeal shim no.1 And anti–squeal shim no.2 From each pad.

1. remove the 2 front disc brake pad support plates from the cylinder mounting.

1. remove the 2 cylinder slide pins from the disc brake cylinder mounting.

1. Remove the 2 bolts and disc brake cylinder mounting.

1. 1
   Place front disc brake cylinder mounting in vise.
2. 2
   using a screwdriver and hammer, remove the 2 bush dust boots from the disc brake cylinder mounting.

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

1. 1
   Place a piece of cloth or similar, between the piston and the disc brake cylinder.
2. 2
   use compressed air to remove the piston from the disc brake cylinder.

1. using a screwdriver, remove the piston seal from the disc brake cylinder.

1. remove the bleeder plug cap and bleeder plug from the disc brake cylinder.

1. check the cylinder bore and piston for rust or scoring.

1. Using a ruler, measure the pad lining thickness.

   Standard thickness: 11.0 Mm (0.433 In.) Minimum thickness: 1.0 Mm (0.039 In.)

1. make sure that they have sufficient rebound, no deformation, cracks or wear, and have had all rust and dirt cleaned off.

1. Using a micrometer, measure the disc thickness.

   Standard thickness: 25.0 Mm (0.984 In.) Minimum thickness: 23.0 Mm (0.906 In.)

1. 1
   Make matchmarks on the front disc and the axle hub.
2. 2
   remove the front disc.

1. aligning the matchmarks, install the front disc.

1. 1
   Temporarily fasten the disc with hub nuts.

   Torque: 103 nvm (1,050 Kgf·cm, 76 ft·lbf)

2. 2
   using a dial indicator, measure the disc runout 10 mm (0.39 In.) Away from the outer edge of the disc.

   Maximum disc runout: 0.05 Mm (0.0020 In.)

3. 3
   if the disc runout is the maximum value or greater, check the bearing play in the axial direction and check the axle hub runout . If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on a ”on–car” brake lathe.

1. temporarily tighten the bleeder plug, and install bleeder plug cap to the disc brake cylinder.

1. 1
   apply the lithium soap base glycol grease on a new piston seal.
2. 2
   install the piston seal to the disc brake cylinder.

1. 1
   apply the lithium soap base glycol grease on the piston.
2. 2
   install the piston to the disc brake cylinder.

1. Apply the lithium soap base glycol grease to a new cylinder boot. Install the cylinder boot to the disc brake cylinder.

1. 1
   Place front disc brake cylinder mounting in vise.
2. 2
   apply the lithium soap base glycol grease to seal surface of 2 new bush dust boots.
3. 3
   using a socket wrench (19 mm) and hammer, drive the 2 bush dust boots to the disc brake cylinder mounting.

1. install the disc brake cylinder mounting lh with the 2 bolts.

   Torque: 106.8 Nvm (1,089 Kgf·cm, 79 ft·lbf)

1. 1
   apply the lithium soap base glycol grease to the sliding part and the seal surface of the 2 cylinder slide pins.
2. 2
   install the 2 cylinder slide pins to the disc brake cylinder mounting.

1. install the 2 front disc brake pad support plates to the cylinder mounting.

1. 1
   apply disc brake grease to each anti–squeal shim no.1.
2. 2
   install anti–squeal shims on each pad.
3. 3
   install the pad wear indicator plate facing upward, and install each pad.

1. 1
   install the disc brake cylinder with the 2 bolts.

   Torque: 34.3 Nvm (350 Kgf·cm, 25 ft·lbf)

   

2. 2
   Install a new gasket and flexible hose with the union bolt.

   Torque: 29 nvm (296 Kgf·cm, 21 ft·lbf)

• gasket has 2 types: 2–piece type and 1–piece type.
• Install the flexible hose lock securely in the lock hole in the disc brake cylinder.

sst 09023–00100

torque: 103 nvm (1,050 Kgf·cm, 76 ft·lbf)