REMOVAL
CAUTION / NOTICE / HINT
HINT:
PROCEDURE
1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID
NOTICE:
Immediately wash off any brake fluid that comes into contact with any painted surfaces.
3. REMOVE FRONT DISC BRAKE ANTI-RATTLE WITH HOLE PIN
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(a) for Pin Hold Clip Type A: (1) Remove the pin hold clip from the 2 front disc brake anti-rattle with hole pins. Text in Illustration
NOTICE: The pin hold clip can be used again if it has sufficient rebound; no deformation or wear; and has had all rust, dirt and foreign matter cleaned off. (2) Remove the 2 front disc brake anti-rattle with hole pins from the disc brake cylinder assembly. (3) Remove the anti-rattle spring from the front disc brake pad. NOTICE: The anti-rattle spring can be used again if it has sufficient rebound; no deformation, cracks or wear; and has had all rust, dirt and foreign matter cleaned off. |
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(b) for Pin Hold Clip Type B: (1) Remove the 2 pin hold clips from the 2 front disc brake anti-rattle with hole pins. Text in Illustration
(2) Remove the 2 front disc brake anti-rattle with hole pins from the disc brake cylinder assembly. (3) Remove the anti-rattle spring from the front disc brake pad. NOTICE: The anti-rattle spring can be used again if it has sufficient rebound; no deformation, cracks or wear; and has had all rust, dirt and foreign matter cleaned off. |
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4. REMOVE FRONT DISC BRAKE PAD KIT
(a) Remove the 2 front disc brake pads with front anti squeal shim from the disc brake cylinder assembly.
5. REMOVE FRONT ANTI SQUEAL SHIM KIT
(a) Remove the 2 front anti squeal shims from each of the front disc brake pads.
6. REMOVE DISC BRAKE CYLINDER ASSEMBLY
(a) Using a union nut wrench 10 mm, separate the brake tube from the disc brake cylinder assembly.
HINT:
Use a container to collect the brake fluid as it drains out.
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(b) Remove the 2 bolts and the disc brake cylinder assembly. |
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7. INSPECT DISC THICKNESS
(a) Using a micrometer, measure the disc thickness.
Standard thickness:
28.0 mm (1.10 in.)
Minimum thickness:
26.0 mm (1.03 in.)
If the disc thickness is less than the minimum, replace the front disc.
8. REMOVE FRONT DISC
(a) Place matchmarks on the front disc and the front axle hub and remove the front disc.
Text in Illustration|
*a |
Matchmark |
Disassembly
InspectionMulti-terrain Select Switch
Components
COMPONENTS
ILLUSTRATION
Removal
REMOVAL
PROCEDURE
1. REMOVE MULTI-TERRAIN SELECT SWITCH (DRIVE MONITOR SWITCH)
(a) Disengage the 2 claws to remove the multi-terrain select switch (drive
monitor switch).
Inspection ...
Data List / Active Test
DATA LIST / ACTIVE TEST
1. DATA LIST
HINT:
Using the Techstream to read the Data List allows values or states of switches,
sensors, actuators and other items to be read without removing any parts. This non-intrusive
inspection can be very useful because intermittent conditions or signals may ...
Manual Shifting Test
MANUAL SHIFTING TEST
1. PERFORM MANUAL SHIFTING TEST
HINT:
Using this test, it can be determined whether a problem is in an electrical
circuit or if it is a mechanical problem in the transmission.
If any abnormalities are found in the following test, the problem is
in the tran ...