Disc Brake System: Service and Repair

INSPECTION
1. Raise vehicle and support the frame.
2. Remove the front wheel.





3. Look through side of caliper to visually check pad thickness. Also check to see if wear indicator is touching the disc assembly. Always replace pads if wear indicator touches rotor.

NOTICE: Hydraulic fluid will damage paint. If fluid gets on a painted surface, wipe off immediately.

REMOVAL





1. Remove the two caliper assembly bolts and pull caliper from disc.
2. Remove the brake flex hose mounting bolt and disconnect the brake flex hose from the caliper.

NOTICE: Do not disassemble the brake flex hose.





3. Remove the brake pads from the adapter.





4. Remove the two adapter mounting bolts and then remove the adapter.





5. Remove the two screws and then remove the disc assembly.

INSPECTION

1. Check for oil or grease on the pads or on the disc assembly.





2. Check pad lining thickness. If below minimum, replace pad.

Minimum Thickness: 0.08 inch (2.0 mm)
New Thickness: 0.37 inch (9.5 mm)

3. Visually check disc for damage or wear.
4. Measure disc thickness. If below minimum, replace disc assembly.

Standard: 0.94 inch (24 mm)
Minimum: .088 inch (22.4 mm)




5. Visually check the piston seal for holes, tears, or other damage. Replace using piston repair kit.

INSTALLATION



1. Place disc assembly on front axle and install the disc screws. Check the disc runout from the outer surface.

Runout: 0.004 inch (0.10 mm) at 4.7 inch (12 cm) from disc center

2. Check that anti-rattle clip is on the adapter and then install the adapter and bolts.
Tighten the bolts to 17 ft. lbs. (23.5 Nm)
3. Place brake pads on adapter.




4. Using a C-clamp or similar device, push the caliper piston into the caliper.
5. Place the caliper assembly in position on the disc assembly.
Tighten the bolts to 72 ft. lbs. (98 Nm)




6. Reconnect the brake flex hose and tighten the mounting bolt.
Tighten the bolt to 17 ft. lbs. (23.5 Nm)




7. Install the tire and bleed the brake system.
8. Pump the brake pedal three times and then check brake movement while rotating the tire.