Repair Procedures

Removal

CAUTION:
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
- Avoid breathing dust particles.
- Never use on air hose or brush to clean brake assemblies.

1. Loosen the front wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheels.
2. Remove the guide rod bolt (B), After raise the caliper assembly (A), support it with a wire.




3. Remove pad shim (A), pad retainer (B) and pad assembly (C) in the caliper bracket.






Inspection

Front Brake Disc Thickness Check
1. Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm) front the brake disc outer circle.

Front brake disc thickness
Standard value : 28 mm(1.10 in)
Limit : 26 mm(1.02 in)

2. Thickness variation should not exceed 0.005mm (0.0002 in) (circumference) and 0.01 mm (0.0004 in)(radius) at any directions.
3. If wear exceeds the limit, replace the discs and pad assemblies on the left and right sides of the vehicle.





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 : 10.5 mm (0.41 in)
Service limit : 2 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 Run Out Check
1. Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the run out of the disc.

Brake disc run out
Limit : 0.03 mm (0.0012 in.) or less (new one)

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





Seizing of Front brake disc
1. Remove the brake disc from hub using an M8 screw(A) if the brake disc has been seized with the hub due to corrosion or overheating.

NOTE:
Be careful not to use a hammer. The disc can be damaged if you remove the disc from the hub by hammering.





Installation

1. Install the pad retainers (A) on the caliper bracket.




2. Install pad shims (A) and the brake pads (B) with the wear indicator on the inside.

CAUTION:
If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency.




3. Insert the piston in the cylinder using the special tool (09581-11000).




4. Push in the piston (A) so that the caliper will fit over the pads. Make sure that the piston boot is in position to prevent damaging it when pivoting the caliper down.
5. Being careful not to damage the pin boot, install the guide rod bolt (B) with the specified torque.




6. If caliper assembly was removed, install the brake hose to the caliper.
7. Refill the master cylinder reservoir to the MAX line.
8. Bleed the brake system.
9. Depress the brake pedal several times to make sure the brakes work, then test-drive.

NOTE:
Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake will restore the normal pedal stroke.

10. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.