Removal and Installation

REMOVAL 

1. Observe the brake fluid level in the reservoir tank. Partially drain the brake fluid if necessary. Refer to Drain and Refill .
2. Remove the front wheel and tire using power tool. Refer to Removal and Installation .
3. Remove the slide pin bolts (A).

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4. Remove the brake caliper from the torque member. Leaving the brake hose attached, reposition the brake caliper aside using wire.
5. Remove the brake pads, shims, and shim covers from the torque member. Remove the pad return springs with the anti-rattle clips from the torque member. Refer to Exploded View .
   CAUTION:

   • Do not deform the pad return springs or anti-rattle clips when removing the anti-rattle clips from the torque member.
   • Do not damage the piston boots.
   • Do not drop the brake pads, shims, or shim covers.
   • Note the position of components during removal to aid with installation.
6. Remove the pad return springs (1) from the anti-rattle clips (2).

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   CAUTION:

   Do not deform the pad return springs.

INSTALLATION 

1. Install the pad return springs (1) to the anti-rattle clips (2).

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   CAUTION:

   Do not deform the pad return springs.

2. Apply Molykote® 7439 grease to the matching surfaces between the torque member, the anti-rattle clips, and the brake pad support plates. Refer to Exploded View .
3. Install the anti-rattle clips with the pad return springs to the torque member.
   CAUTION:

   • Do not deform the anti-rattle clips or the pad return springs.
   • Verify that the anti-rattle clips are secured properly to the torque member.
4. Apply Molykote® AS-880N grease (A) to the matching surfaces between the inner shim, the inner shim cover (1) and the brake caliper, as well as to the matching surfaces between the outer shim, the outer shim cover (2) and the brake caliper.

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5. Install the brake pads, shims, and shim covers to the anti-rattle clips with the pad return springs on the torque member.

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   CAUTION:

   The inner pads and the outer pads have a pad return system. Securely push each pad return spring (1) into the disc brake rotor side of each brake pad (2).

6. Using a suitable tool, press the pistons into the brake caliper.
   CAUTION:

   Do not damage the piston boots.

7. Install the brake caliper to the torque member.
8. Install the slide pin bolts. Tighten the slide pin bolts to the specified torque. Refer to Exploded View .
9. Depress the brake pedal several times and verify that drag does not exist.
10. Install the front wheel and tire. Refer to Removal and Installation .
11. Check brake fluid level and refill as necessary. Refer to Inspection .

INSPECTION AFTER INSTALLATION 

1. Check the drag of front disc brake. If any drag is found, follow the procedure described below.
2. Remove the brake pads.
3. Using a suitable tool, press the pistons into the brake caliper body.
   CAUTION:

   Do not damage the piston boots.

4. Install the brake pads.
5. Depress the brake pedal several times.
6. Check the drag of front disc brake again. If any drag is found, disassemble the brake caliper body. Refer to Disassembly and Assembly .
7. Burnish contact surfaces after replacing brake pads or if a soft pedal occurs at very low mileage. Refer to Inspection and Adjustment .