Repair Procedures

Removal

1. Remove the front wheel & tire.

Tightening torque :
88.3 - 107.9N.m (9.0 - 11.0kgf.m, 65.1 - 79.6lb-ft)




2. Remove the split pin (A) and castle nut (B).

Tightening torque :
196.1 - 274.6N.m (20 - 28kgf.m, 144.7 - 202.5lb-ft)




3. Loosen the hose eye-bolt (A) and caliper mounting bolts, then remove the front caliper assembly (B).

Tightening torque :
Brake hose to caliper:
16.7 - 19.6N.m (1.7 - 2.0kgf.m, 12.3 - 14.5lb-ft)
Caliper assembly to knuckle:
73.5 - 83.4N.m (7.5 - 8.5kgf.m, 54.2 - 61.5lb-ft)




4. Remove the front brake disc by loosening the screws (A).






Replacement

Front Brake Pads
1. Loosen the guide rod bolt (A) and pivot the caliper (B) up out of the way.




2. Replace shims (A), pad retainers (B), and brake pads (C).




3. Push the piston in the cylinder using a SST (09581-11000)




4. Pivot the caliper down and tighten the guide rod bolt.

Tightening torque :
25.5 - 37.3N.m (2.6 - 3.8kgf.m, 18.8 - 27.5lb-ft)

Inspection

Front brake disc thickness check
1. Check the brake pads for wear and fade.
2. Check the brake disc for damage and cracks.
3. Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm) from the brake disc outer circle.

Brake disc thickness
- Standard : 28 mm (1.10 in.)
- Service Limit : 26.4 mm (1.04 in.)
Deviation: Less than 0.01 mm (0.0004 in.)




4. If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.

CAUTION:
When the thickness is less than the value of the service limit of each model plus 0.5mm, replace the brake discs on both sides with new ones without machining.

Front brake disc runout check
1. Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.

Brake disc runout
Standard: 0.03 mm (0.00118 in.) or less




2. If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.
3. If the runout does not exceed the limit specification, install the brake disc after turning it 180° and then check the runout of the brake disc again.
4. If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.

Installation

1. Installation is the reverse of removal.
2. Use a SST (09581-11000) when installing the brake caliper assembly.




3. After installation, bleed the brake system.