Front Disc Brake

Components and Component Location

COMPONENTS

Repair Procedures

DEPOSIT

1. 1
   Remove the front wheel and tire assembly (A) from the hub.

   Tightening torque: 88.2 - 108 N·m

   

2. 2
   Loosen the guide pin bolt (B) and rotate the caliper housing (A) upward.

   Tightening torque: 21.6 ~ 31 N·m

   

3. 3
   Remove the pad return spring (A) and separate the brake pad.

   

4. 4
   Loosen the banjo bolt of the hose (A) and the caliper mounting bolts (B), then remove the front caliper assembly. Tightening torque: Brake hose to caliper: 24.5 ~ 29 N·m; Caliper to knuckle: 78.5 ~ 98 N·m

   

5. 5
   Remove the front brake disc by removing the screws.

   Tightening torque: 4.9 - 5.8 N·m

   

Brake Pad Replacement

1. 1
   Remove the front wheel and tire assembly (A) from the hub.

   Tightening torque: 88.2 - 108 N·m

   

2. 2
   Loosen the guide pin bolt (B) and rotate the caliper housing (A) upward.

   Tightening torque: 21.6 ~ 31 N·m

   

3. 3
   Replace the pad return spring (A) and the brake pad.

   

4. 4
   Use the special service tool (09581-2T100) when installing the brake caliper.

   

5. 5
   Position the caliper housing (A) on the caliper bracket and tighten the guide rod bolts (B).

   Tightening torque: 21.6 ~ 31 N·m

   

Inspection

1. 1
   Inspect the brake pads for wear and discoloration.
2. 2
   Inspect the brake disc for damage and cracks.
3. 3
   Remove all rust and contamination from the surface, then measure the disc thickness at at least 8 points located at the same distance (5 mm) from the outer edge of the brake disc. Front brake disc thickness - Standard: 25 mm (0.98 in) - Service limit: 23.4 mm (0.92 in) - Variation: less than 0.005 mm (0.0002 in)

   

4. 4
   If wear exceeds the limit, replace the disc/pad assembly of both the left and right sides of the vehicle.
5. 5
   Check pad wear. Measure the pad thickness, and if it is less than specified, replace the pads. Pad thickness - Standard: 11 mm (0.43 in) - Service limit: 2.0 mm (0.0787 in)
6. 6
   Check that grease is applied to the sliding contact points and that the brake pad and backing plate are not damaged.

   

7. 7
   Place a dial indicator approximately 5 mm (0.2 in) from the outer edge of the brake disc and measure the disc runout. Brake disc runout - Limit: 0.04 mm (0.00157 in) or less (new part)

   

8. 8
   If disc runout exceeds the maximum specified value, replace the disc, then measure the runout again.
9. 9
   If the out-of-round condition does not exceed the usable limit, rotate the disc 180° and check the runout again.
10. 10
    If changing the position does not eliminate the out-of-round condition of the brake disc, replace the brake disc.

REMEDY

1. 1
   To install, perform the removal procedure in reverse order.
2. 2
   Use the special service tool (09581-2T100) when installing the brake caliper.

   

3. 3
   After installation, bleed the brake system. (Refer to Brake System - "Brake System Bleeding")