Front Brake

FRONT BRAKE

1 Blead screw 
2 Pad spring
3  Pad retaining pin
4  Caliper piston assembly (Replace as a set)
5  Caliper
6 Brake pads (Replace as a set)
7 Copper washer
8 Union bolt
9 Master cylinder kit {Replace as a set)

PAD SPRING

* Install the pad spring with its longer tangs facing upwards.

PAD THICKNES: Std.: 5.5 mm (0.22 in) 
WEAR LIMIT: 0.5 mm (0.02 in)
BRAKE FLUID TYPE: DOT =3

CAUTION: Disc brake components rarely require disassembly. Do not:
• Disassemble components unless absolutely necessary.
• Use solvents on internal brake component.
• Use contaminated brake fluid for cleaning. Use only clean brake fluid.
• Allow brake fluid to come in contact with the eyes otherwise eye injury may occur.
• Allow brake fluid to contact painted surfaces or plastic parts otherwise damage may occur.
• Disconnect any hydraulic connection otherwise the entire system must be disassembled, drained, cleaned, and then properly filled and bled after reassembly.

BRAKE PAD REPLACEMENT

It is not necessary to disassemble brake caliper and brake hose to replace brake pads.

1. Remove:
• Cover
• Circlips 1
• Pad retaining pins 2
• Pad spring 3
• Pads 4

2. Install pads. Reverse removal steps.

NOTE:
• Install the pad spring with its longer tangs facing upwards.
• Replace pads as a set if either is found to be worn to the wear limit.

CALIPER DISASSEMBLY

1.  Remove:
• Brake hose 1
• Caliper securing bolts 2
• Brake pads

2.  Remove caliper piston assembly. Use compressed air and proceed carefully.

Caliper piston removal steps:

• Using a rag, lock the right side piston.

• Blow compressed air into the hose joint opening to force out the left side piston from the caliper body.

• Remove the dust and piston seals and reinstall the piston.

• Repeat previous step to force out the right side piston from the caliper body.

DO NOT LOOSEN "A"

• Cover piston with rag and use extreme caution when expelling piston from cylinder. 
• Never attempt to pry out piston.

MASTER CYLINDER DISASSEMBLY

1. Remove:
• Brake light switch 1 Push 2 the brake light switch stopper. 
• Brake hose 3
• Brake lever 4 and spring
• Master cylinder assembly 5

2. Remove:
• Cap 1  Drain remaining fluid.
• Master cylinder dust boot 2
• Circlip 3
• Master cylinder cup assembly

NOTE:
Be sure to reinstall the larger diameter lips of the cylinder cups first.

4 Master Cylinder Kit

INSPECTION AND REPAIR

1. Inspect the caliper piston assembly. Replace if there are scratches or other damage. Replace the brake pads as a set if worn below wear limits 1.

Brake Pad Wear Limit: 0.5 mm (0.02 in)

2 Wear indicator

2. Inspect master cylinder body and caliper body. Replace if scratched. Clean all passages with new brake fluid. Replace brake hoses if cracked, frayed, damaged or over 4 years old.

NOTE:
See Stainless Steel Brake Line Guide for dimensions.

3. Measure: 
• Deflection 1 
• Thickness 2 

Turn or replace rotors if out of specification.

Maximum Deflection: 0.15 mm (0.006 in)
Minimum Disc Thickness: 4.5 mm (0.177 in)

ASSEMBLY

Caliper

NOTE:
• All internal parts should be cleaned in new brake fluid only.
• Internal parts should be lubricated with brake fluid when installed.
• Replace the piston and dust seals whenever the caliper is disassembled.

1. Install:
• Piston seal 1
• Dust seal 2
• Piston 3
• Pad spring 4
• Brake pads 5
• Caliper assembly

2. Tighten the caliper securing bolts 1 and brake hose union bolt 2

Caliper: 35 Nm (3.5 m-kg, 25ft-lb)

Brake Hose: 26 Nm (2.6 m-kg, 19 ft-lb)

3. Bleed the air completely. 

Master Cylinder 

1. Assemble the master cylinder

Union Bolt 1 : 26 Nm (2.6m-kg, 19 ft-lb) 
Master Cylinder Holding Bolt 2 : 10Nm(1.0m-kg, 7.2ft-lb)

3 Copper washer 4 Master cylinder kit

2. Bleed the air completely.

AIR BLEEDING

Bleed the brake system if:
• The system has been disassembled.
• A brake hose has been loosened or removed.
• The brake fluid is very low.
• The brake operation is faulty.

WARNING:
A dangerous loss of braking performance may occur if the brake system is not properly bled.

Air bleeding steps:
a.  Add proper brake fluid to the reservoir.
b.  Install diaphragm.
Be careful not to spill any fluid or allow the reservoir to overflow.
c.  Connect the clear plastic tube 1 (4.5 mm, 3/16 in inside dia.) tightly to the caliper bleed screw 2.
d.  Place the other end of the tube into a container.
e.  Slowly apply the brake lever several times.
f.   Pull the lever in. Hold the lever in position.
g.  Loosen the bleed screw and allow the lever to travel towards its limit.
h. Tighten the bleed screw when the leverlimit has been reached; then release the lever. 
i. Repeat steps e to h until all of the air bubbles have been removed from the system.

NOTE:
If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in system have disappeared.