Overhaul

FRONT BRAKE

COMPONENTS:

DISASSEMBLY





1. REMOVE CYLINDER BOOT
(a) Using a screwdriver with its tip wrapped in protective tape, remove the set ring and cylinder boot from the disc brake cylinder.





2. REMOVE FRONT DISC BRAKE PISTON
(a) Place a shop rag or piece of cloth between the piston and disc brake cylinder.
(b) Apply compressed air to remove the piston from the disc brake cylinder.

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

NOTICE: Do not spatter the brake fluid.





3. REMOVE PISTON SEAL
(a) Using a screwdriver with its tip wrapped in protective tape, remove the piston seal from the disc brake cylinder.

NOTICE: Do not damage the inner surface or piston seal groove of the cylinder.

4. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
5. REMOVE FRONT DISC BRAKE BLEEDER PLUG

REASSEMBLY
1. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
2. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
3. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal onto the disc brake cylinder.

NOTICE: Securely install the piston seal into the groove of the disc brake cylinder.





4. INSTALL FRONT DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the piston and a new cylinder boot.
(b) Install the cylinder boot onto the piston.
(c) Install the piston into the disc brake cylinder.

NOTICE: Do not forcibly install the piston into the disc brake cylinder.





5. INSTALL CYLINDER BOOT
(a) Install the cylinder boot into the disc brake cylinder.

NOTICE: Securely install the cylinder boot into the groove of the disc brake cylinder.

(b) Using a screwdriver, install a new set ring.

NOTICE: Do not damage the cylinder boot.