Repair Procedures

Removal

1. Remove the front wheel & tire.

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

2. Remove the hose eyebolt (B) and caliper mounting bolts (C), then remove the front caliper assembly (A).

Tightening torque:
Brake hose to caliper:
24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7 lb-ft)
Caliper assembly to knuckle:
78.5 - 98.1 N.m (8.0 - 10.0 kgf.m, 57.9 - 72.3 lb-ft)




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






Replacement

Front brake pads
1. Remove the guide rod bolt (B) and pivot the caliper (A) up out of the way.

Tightening torque:
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)




2. Replace pad shim (D), pad retainers (C) and brake pads (B) in the caliper bracket (A).






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 dise surface. Measure the disc thickness at 8 points around the dise and at least (5mm) from the outer diameter of the disc.

Brake disc thickness
Standard: 28mm (1.10in)
Service limit: 26.4mm (1.039in)
Deviation: Less than 0.005mm (0.0002in)




4. If the wear exceeds the limit, replace the discs and brake pads.

Front Brake Pad Check
1. Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.

Pad thickness
Standard value: 11 mm (0.43 in)
Service limit: 2.0 mm (0.0787 in)

2. Check that grease is applied, to sliding contact points and the pad and backing metal for damage.





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
Limit: 0.025 mm (0.00098 in.) or less (new one)




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, pull the disc, turn the disc and reinstall on the heb. Then recheck 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 the SST (09581-11000) to spread the caliper then install the caliper with the brake pads.




3. After installation, bleed the brake system.