Brake

Front brake

Front brake
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-2
Removal (normal type). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-5
Removal (brembo type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-8
Disassembly (normal type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-9
Disassembly (brembo type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-10
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-11
Assembly (normal type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-12
Assembly (brembo type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-13
Installation (normal type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-14
Installation (brembo type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-17
Front brake flexible hose
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-19

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Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-20

FB
 FB–2 Front brake － Front brake

Front brake
Front brake
Brake

Exploded view

Normal type
26 {265,59.0}
Union bolt
Front flexible hose No.1
*1
80 {816,59.0}

*2
135 {1377,99.6}

x2
Gasket
Front disc brake cylinder Spring(L)
ASSY LH
x2
Boots (pins)
26 {265,19.2}

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Front disc brake
cylinder slide pin Front disc brake
cylinder mounting LH
Spring (pad)
Front disc brake cylinder
slide pin No.2

Boots (pins)
Bushing

Shim

Front disc Front disc

Shim brake pad

*1: Width across flat 17 mm {0.6693 in}

FB N*m {kgf*cm,ft*lbf} : Tightening torque *2: Width across flat 19 mm {0.748 in}
Rubber grease (NIGLUBE RX-2) or equivalent
Non-reusable parts MP grease No.2 or equivalent

BR-10630
 Front brake － Front brake
FB–3

Brembo type

Union bolt
26 {265,19.2}
Front flexible hose No.1

120 {1224,88.5}

Gasket

Caliper body ASSY

Cross spring

Tie bar
Guide plate

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Clip slide pin

Steering knuckle

Shim disc brake Pin disc brake

front outer

Shim disc brake

front inner

Pad disc brake

front inner

Pad disc brake

front outer
Disc rotor
Shim disc brake
front inner

Shim disc brake

front outer

N*m {kgf*cm,ft*lbf} : Tightening torque Disc brake grease II or equivalent

Non-reusable parts MP grease No.2 or equivalent FB

BR-10393
 FB–4 Front brake － Front brake

Normal type

8.0 {82,5.9}

Bleeder screw

Cap bleeder
Front disc brake cylinder
ASSY LH

Piston seal

Front disc brake piston

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Cylinder boot

Cylinder boot
Piston seal

Front disc brake piston

N*m {kgf*cm,ft*lbf} : Tightening torque Rubber grease (RENOLIT rubber grease JP)
or equivalent
Non-reusable parts

BR-10397

FB
 Front brake － Front brake
FB–5

Brembo type
Cap bleeder

Bleeder screw
20 {203,14.8}

Caliper body

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Piston seal

Piston disc brake

Piston boot

Piston boot
Piston disc brake

Piston seal

N*m {kgf*cm,ft*lbf} : Tightening torque Rubber grease (RENOLIT rubber grease JP)
or equivalent
Non-reusable parts

BR-10398

Removal (normal type)

NOTE:
• The following procedure is for LH side.
• Service the LH side and the RH side using the same procedure.
1. Removal of front tire
2. Draining of brake fluid
CAUTION:
Do not let brake fluid come into contact with the painted surface. If it happens, wash it out immediately.
FB
 FB–6 Front brake － Front brake

3. Disconnection of front flexible hose No.1

(1) Remove a union bolt and 2 gaskets to disconnect the front flexible
hose No.1 from the front disk brake cylinder ASSY LH.

4. Removal of front disc brake cylinder ASSY LH

(1) Remove 2 bolts and then remove the front disc brake cylinder
ASSY LH.

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5. Removal of front disc brake pad
(1) Remove the disc brake pad from the front disc brake cylinder mounting LH.
(2) Remove the shim from each pad.


BR-10154

Captions in illustration
*1 Shim *2 Disc brake pad

6. Removal of spring (L)

(1) Remove the spring (L) from the front disc brake cylinder mounting

FB LH.
 Front brake － Front brake
FB–7

7. Removal of spring (pad)

(1) Remove the spring (pad) from the front disc brake cylinder mount-
ing LH.

8. Removal of front disc brake cylinder slide pin

(1) Remove the front disc brake cylinder slide pin from the front disc
brake cylinder mounting LH.

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9. Removal of front disc brake cylinder slide pin No.2
(1) Remove the front disc brake cylinder slide pin No.2 from the front
disc brake cylinder mounting LH.

10. Removal of boot (pin)

(1) Remove the boot (pin) from the front disc brake cylinder mounting
LH.

11. Removal of bushing

(1) Using a thin flat tip screwdriver wrapped with a protective tape,
remove the bushing from the pin (B).
Captions in illustration FB
*1 Protective tape

 FB–8 Front brake － Front brake

12. Removal of front disc brake cylinder mounting LH

(1) Remove 2 bolts and then the front disc brake cylinder mounting
LH.

13. Removal of front disc

(1) Put alignment marks on the front disc and front axle hub. (It is not
C necessary when replacing the disc).
Captions in illustration
*a Alignment marks

(2) Remove the front disc.

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Removal (brembo type)
NOTE:
• The following procedure is for LH side.
• Service the LH side and the RH side using the same procedure.
1. Removal of front tire
2. Draining of brake fluid
CAUTION:
Do not let brake fluid come into contact with the painted surface. If it happens, wash it out immediately.
3. Removal of pad disc brake front
 (1) Remove the clip slide pin, and remove the pin disc brake and
cross spring.
(2) While pushing back the piston using a wrench, remove the pad
disc brake front.
Captions in illustration
  *1 Clip slide pin
*2 Pin disc brake
*3 Cross spring
*4 Pad disc brake
 BR-10101

4. Disconnection of front flexible hose No.1

(1) Remove the union bolt and 2 gaskets, and then remove the front
flexible hose No. 1 from the caliper body ASSY.

FB

BR-10102
 Front brake － Front brake
FB–9

5. Removal of caliper body ASSY

(1) Remove the 2 bolts, and remove the caliper body ASSY and tie
bar.
NOTE:
If it is hard to be removed, use the SST.
SST 09961-01270

BR-10103

6. Removal of disc rotor

(1) Put alignment marks on the disc rotor and front axle hub. (It is not
C necessary when replacing the disc).
Captions in illustration
*a Alignment marks

(2) Remove the disc rotor.

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Disassembly (normal type)
1. Removal of cylinder boot
(1) Remove 2 cylinder boots.
 CAUTION:
To prevent the front disc brake piston from being scratched, always
 remove the boot with hands without using a tool like a screwdriver.
Captions in illustration
*1 Cylinder boot
*2 Front disc brake piston

2. Removal of front disc brake piston

(1) Put a wooden block between the pistons of the cylinder ASSY to
prevent the pistons from popping out.
Captions in illustration
*1 Wooden block
*a 30mm {1.181in}

(2) Using an air gun, gradually blow air into the applicable part to
remove the 2 front disc brake pistons from the cylinder.
WARNING:
Be careful not to pinch your fingers.
CAUTION:
 Be careful not to spill brake fluid.
NOTE: FB
C Replace the front disc brake cylinder ASSY, if the front disc brake
piston is damaged.
(3) Remove the wooden block.
 FB–10 Front brake － Front brake

3. Removal of piston seal

 (1) Using a thin flat tip screwdriver, remove 2 piston seals from the cyl-
inder ASSY.
NOTE:
Wrap the tip of the thin flat tip screwdriver with a protective tape.
Captions in illustration
*1 Protective tape

CAUTION:
Do not damage inside the cylinder and the seal groove.

4. Removal of cap bleeder

(1) Remove the cap bleeder from the bleeder screw.
5. Removal of bleeder screw
(1) Remove the bleeder screw.

Disassembly (brembo type)

1. Removal of piston boot
(1) Remove the four piston boots.

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BR-10104

2. Removal of piston disc brake

 (1) Put a wooden block between the pistons of the caliper body to pre-
vent the pistons from popping out.
Captions in illustration
*1 Wooden block
*a 30mm {1.181in}

(2) Using an air gun, gradually blow air into the applicable part to
remove the 4 piston disc brake from the cylinder.
WARNING:
Be careful not to pinch your fingers.
CAUTION:
Be careful not to spill brake fluid.
NOTE:
When the piston disc brake is damaged, replace the caliper body.
(3) Remove the wooden block.
D
BR-10105

3. Removal of piston seal

(1) Using a thin flat tip screwdriver, remove the 4 piston seals from the

FB caliper body.
NOTE:
Wrap the tip of the thin flat tip screwdriver with a protective tape.
Captions in illustration
*1 Protective tape

 CAUTION:
Do not damage inside the cylinder and the seal groove.

BR-10106
 Front brake － Front brake
FB–11

4. Removal of cap bleeder

(1) Remove the cap bleeder from the bleeder screw.
5. Removal of bleeder screw
(1) Remove the bleeder screw.

Inspection
1. Disc brake piston and cylinder check
(1) Check that there is no damage on the side of the disc brake piston and the cylinder wall.
2. Disc brake pad thickness check
• Normal type
Limit: 1.5mm {0.059in}
Reference value: : 11.0mm {0.433in} (New)
• Brembo type
Limit: 1.2mm{0.047in}
Reference value: 8.8mm {0.346in}

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3. Front disc thickness check
• Normal type
Limit: 22.0mm {0.866in}
Reference value: : 24.0mm {0.945in} (New)
• Brembo type
Limit: 28 mm {1.102 in}
Reference value: 30mm {1.181in}

4. Disc runout check

(1) Before checking the disc runout, check the hub & bearing ASSY play (Refer to AD - 11) and runout (Refer to AD - 11).
(2) Install the front disc to the axle hub and secure it with 5 wheel nuts.
Standard value:T=120N·m {1224kgf·cm} {88.5ft·lbf}

(3) Using a dial gauge, set at 10 mm {0.394 in} inside from the disc
outer periphery to check the front side runout.

• Normal type
Limit: 0.05mm {0.002in}
• Brembo type
Limit: 0.075mm{0.003in}
Captions in illustration
*1 Dial gauge

CAUTION:
• Do not bring the magnetized part of the dial gauge close to the
BR-10021
axle hub or speed sensor.
• Install the dial gauge to the shock absorber.
• When the runout exceeds the limit, change the disc and axle posi- FB
tions to minimize the runout and install them. If the runout still
exceeds the limit even after changing the positions, replace the
disc with a new one.
 FB–12 Front brake － Front brake

(4) Set the dial gauge at 10 mm {0.394 in} inside from the disc rotor
outer periphery, and rotate the disc rotor to check the back side
runout.
• Normal type
Limit: 0.05mm {0.002in}
• Brembo type
Limit: 0.075mm{0.003in}
NOTE:
<Example of magnet stand and dial gauge installation>

BR-10112

(5) If the disc rotor runout exceeds service limit, grind the disc rotor.
(6) Check the disc rotor thickness after grinding. (Refer to FB - 11)

Assembly (normal type)

1. Temporary tightening of bleeder screw
(1) Temporarily tighten the bleeder screw to the caliper body.
2. Installation of cap bleeder
(1) Install the cap bleeder to the bleeder screw.

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3. Installation of piston seal
(1) Apply rubber grease all around 2 new piston seals.
Captions in illustration

Rubber grease (RENOLIT rubber grease JP) or equivalent

(2) Securely install 2 piston seals to the disc brake cylinder grooves.

4. Installation of front disc brake piston

(1) Apply rubber grease to a new cylinder boot.
 Captions in illustration
*1 Cylinder boot
*2 Front disc brake piston


Rubber grease (RENOLIT rubber grease JP) or equivalent

(2) Securely install the cylinder boot to the front disc brake piston
groove.

FB (3) Apply a thin coat of rubber grease to the outer peripheries of 2

front disc brake pistons, and install them to the front disc brake cyl-

 inder ASSY LH.
CAUTION:
Do not push the front disc brake piston in with excessive force.

5. Installation of cylinder boot

(1) Securely install the cylinder boot to the front disc brake cylinder ASSY LH groove.
 Front brake － Front brake
FB–13

Captions in illustration
*1 Cylinder boot *2 Front disc brake cylinder ASSY LH
*3 Front disc brake piston - -

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Assembly (brembo type)
1. Temporary tightening of bleeder screw
(1) Temporarily tighten the bleeder screw to the caliper body.
2. Installation of cap bleeder
(1) Install the cap bleeder to the bleeder screw.
3. Installation of piston seal
(1) Apply rubber grease all around 2 new piston seals.
Captions in illustration

Rubber grease (RENOLIT rubber grease JP) or equivalent

(2) Securely install 4 piston seals to the caliper body grooves.

BR-10107

4. Installation of piston-disc brake

(1) Apply rubber grease to a new piston boot.
(2) Securely install the piston boot to the piston disc brake grooves.
(3) Apply a thin coat of rubber grease to the outer periphery of the 4 piston disc brake, and install to the caliper body.
CAUTION:
Do not push the piston-disc brake in with excessive force. FB
(4) Securely install the piston boot to the caliper body grooves.
 FB–14 Front brake － Front brake

 

   

BR-10108

Captions in illustration
*1 Piston boot *2 Piston disc brake

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*3 Caliper body Rubber grease (RENOLIT rubber grease JP) or equivalent

Installation (normal type)

NOTE:
• The following procedure is for LH side.
• Service the LH side and the RH side using the same procedure.
1. Pushing back of piston disc brake
As necessary, push back the piston disc brake using the disc brake piston tool.
CAUTION:
When the piston disc brake is pushed back, the clearance between pad disc brake and brake disc becomes large and the brake
pedal pressure becomes soft.
After installation of the front tires, be sure to press the brake pedal several times to adjust the clearance and pedal pressure.
2. Installation of front disc
(1) When removing/installing the front disc
(a)Aligning the mark which you put at the time of removal, install the front disc to the axle hub.
(2) When replacing the front disc
(a)Check the disc runout (Refer to FB - 11) and install the front disc to the axle hub.
(3) Temporarily tighten the wheel nut to secure the front disc to the axle hub.
3. Installation of front disc brake cylinder mounting LH
(1) Install the front disc brake cylinder mounting LH with 2 new bolts.
Standard value:Width across flat 17 mm {0.6693 in}
T=80N·m {816kgf·cm} {59.0ft·lbf}
Width across flat 19 mm {0.748 in}
T=135N·m {1377kgf·cm} {99.6ft·lbf}

FB
Front brake － Front brake
FB–15

4. Installation of boots (pins)

(1) Apply rubber grease all around the engaging parts of new 2 boots
(pins).
Captions in illustration

Rubber grease (NIGLUBE RX-2) or equivalent

NOTE:
Apply 1.5±2.0g of rubber grease (NIGLUBE RX-2) per 1 front disc
brake bushing dust boot.
(2) Install 2 front disc brake bushing dust boots to the front disc brake
cylinder mounting LH.

5. Installation of bushing
(1) Apply a thin coat of rubber grease all around the contacting sur-
face of the new bushing and the front disc brake cylinder slide pin

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No.2.
Captions in illustration

Rubber grease (NIGLUBE RX-2) or equivalent

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

6. Installation of front disc brake cylinder slide pin No.2

Captions in illustration

Rubber grease (NIGLUBE RX-2) or equivalent

(1) Apply a thin coat of rubber grease all around the engaging part
and the sliding part of the front disc brake cylinder slide pin No.2.
(2) Install the front disc brake cylinder slide pin No.2 to the carrier.

7. Installation of front disc brake cylinder slide pin

Captions in illustration

Rubber grease (NIGLUBE RX-2) or equivalent

(1) Apply a thin coat of rubber grease all around the engaging part
and the sliding part of the front disc brake cylinder slide pin.
(2) Install the front disc brake cylinder slide pin to the carrier.
FB
 FB–16 Front brake － Front brake

8. Installation of spring (L)

NOTE:
Before installation, remove mud, foreign matter, and rust from front disc
brake cylinder ASSY LH and front disc brake cylinder mounting LH.
(1) Apply a thin coat of MP grease No.2 or equivalent to the part
where the disc brake pad kit FR for the spring (L) contacts.
(2) Install the spring (L) to the front disc brake cylinder mounting LH.
Captions in illustration

MP grease No.2 or equivalent

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BR-01149

9. Installation of spring (pad)

NOTE:
Service the spring (pad) in the same procedures for the spring (L).
10. Installation of front disc brake pad
(1) Install the front disc brake pad to the shim.
(2) Install the disc brake pad to the carrier.


BR-10154

Captions in illustration
*1 Shim *2 Disc brake pad

FB
 Front brake － Front brake
FB–17

11. Installation of front disc brake cylinder ASSY LH

(1) Install the front disc brake cylinder ASSY LH to the carrier with 2
bolts.
Standard value:T=26N·m {265kgf·cm} {19.2ft·lbf}

12. Connection of front flexible hose No.1

(1) Using a new union bolt, connect the front flexible hose No.1 to the disc brake cylinder ASSY via 2 new gaskets.
Standard value:T=26N·m {265kgf·cm} {19.2ft·lbf}
13. Brake fluid refill (Refer to BR - 8)
14. Air bleeding of brake system (Refer to BR - 8)
15. Brake fluid leak check
16. Brake fluid level check (Refer to BR - 12)
17. Installation of front tire

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Standard value:T=120N·m {1224kgf·cm} {88.5ft·lbf}

Installation (brembo type)

NOTE:
• The following procedure is for LH side.
• Service the LH side and the RH side using the same procedure.
1. Pushing back of piston disc brake
As necessary, push back the piston disc brake using the disc brake piston tool.
CAUTION:
When the piston disc brake is pushed back, the clearance between pad disc brake and brake disc becomes large and the brake
pedal pressure becomes soft.
After installation of the front tires, be sure to press the brake pedal several times to adjust the clearance and pedal pressure.
2. Installation of disc rotor
(1) When removing/installing disc rotor
(a)Aligning the mark which you put at the time of removal, install the disc rotor to the axle hub.
(2) When replacing the front disc
(a)Check the disc runout (Refer to FB - 11) and install the disc rotor to the axle hub.
(3) Temporarily tighten the wheel nut to secure the disc rotor to the axle hub.
3. Installation of caliper body ASSY
(1) Install the caliper body ASSY and tie bar with 2 bolts.
CAUTION:
When installing the caliper body ASSY and tie bar, temporarily tighten
with 2 bolts as far as it can be turned by hand, and then tighten to the
specified torque.
NOTE:
If it is hard to tighten, use the SST.
SST 09661-01270
Standard value:T=120N·m {1224kgf·cm} {88.5ft·lbf} FB
BR-10103
 FB–18 Front brake － Front brake

4. Installation of pad disc brake front

(1) Apply a thin coat of grease to the side surface of pad disc brake
front, both surfaces of shim disc brake front inner and shim instal-
lation surface of pad disc brake front.
Captions in illustration

Disc brake grease II or equivalent

MP grease No.2 or equivalent

(2) Install the pad disc brake front.

NOTE:
Install so that the arrow faces downward.
(3) Install the cross spring, pin disc brake and clip slide pin.

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BR-10389

5. Connection of front flexible hose No.1

(1) Using a new union bolt, connect the front flexible hose No. 1 to the caliper body ASSY via 2 new gaskets.
Standard value:T=26N·m {265kgf·cm} {19.2ft·lbf}
6. Brake fluid refill (Refer to BR - 8)
7. Air bleeding of brake system (Refer to BR - 8)
8. Brake fluid leak check
9. Brake fluid level check (Refer to BR - 12)
10. Installation of front tire
Standard value:T=120N·m {1224kgf·cm} {88.5ft·lbf}

FB
 Front brake － Front brake flexible hose
FB–19

Front brake flexible hose

Front brake
Brake

Exploded view

15 {155,11.1}

Front flexible hose No.1

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33 {337,24.3}

26 {265,19.2}
Union bolt
Gasket

N*m (kgf*cm, ft*lbf) : Tightening torque

Non-reusable parts

BR-10018
FB
Removal
NOTE:
• The following procedure is for LH side.
• Service the LH side and the RH side using the same procedure.
• The procedures described below are for the normal type. For the brembo type, perform the same procedures as the normal
type.
1. Removal of front tire
 FB–20 Front brake － Front brake flexible hose

2. Draining of brake fluid

CAUTION:
Do not let brake fluid come into contact with the painted surface. If it happens, wash it out immediately.
3. Removal of front flexible hose No.1
(1) Remove the bolt and disconnect the front flexible hose No.1 from
the front shock absorber ASSY.

(2) Remove the union bolt and 2 gaskets, and then remove the front
flexible hose No.1.

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(3) Secure the flexible hose No.1 with a spanner, and disconnect the
brake tube using a flare-nut wrench.
CAUTION:
• Do not bend or damage the brake tubes.
• Do not let foreign matter including dirt and dust enter the connec-
tion part of the brake tube.
(4) Remove the clip.
(5) Remove the front flexible hose No.1.

Installation
NOTE:
• The following procedure is for LH side.
• Service the LH side and the RH side using the same procedure.
• The procedures described below are for the normal type. For the brembo type, perform the same procedures as the normal
type.
1. Installation of front flexible hose No.1
(1) With a new clip, install the front flexible hose No.1.

FB CAUTION:
Securely attach the clip as far as it will go.
(2) Secure the flexible hose No.1 with a spanner, and connect the brake tube to the front flexible hose No.1 using a flare-nut
wrench.
Standard value:T=15N·m {155kgf·cm} {11.1ft·lbf}
CAUTION:
• Do not bend or damage the brake tubes.
• Do not let foreign matter including dirt and dust enter the connection part of the brake tube.
(3) With a bolt, install the front flexible hose No.1 to the front shock absorber ASSY.
 Front brake － Front brake flexible hose
FB–21

Standard value:T=33N·m {337kgf·cm} {24.3ft·lbf}

(4) Using a new union bolt, install the front flexible hose No.1 to the disc brake cylinder ASSY via 2 new gaskets.
Standard value:T=26N·m {265kgf·cm} {19.2ft·lbf}
2. Brake fluid refill (Refer to BR - 8)
3. Air bleeding of brake system (Refer to BR - 8)
4. Brake fluid leak check
5. Brake fluid level check (Refer to BR - 12)
6. Installation of front tire
Standard value:T=120N·m {1224kgf·cm} {88.5ft·lbf}

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FB
 FB–22 Front brake － Front brake flexible hose

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FB