Front Disc Brake Repair Procedures

Removal

1. 1
   Remove the front wheel and tire. Remove the front wheel and tire.

   Tightening torque: 88.3 ~ 108 N·m

2. 2
   Loosen the hose union bolt (C) and guide pin bolts (B), then remove the front caliper body (A). Tightening torque: Brake hose to caliper (C): 24.5 – 29 N·m Guide pin bolts (B): 21.6 – 31 N·m

   

3. 3
   Remove the pad spring (D), pad retainers (C), and brake pads (B) from the caliper bracket (A).

   

4. 4
   Loosen the caliper mounting bolts (B) and remove the caliper bracket (A).

   Tightening Torque: 78.5 ~ 98 N·m

   

5. 5
   Remove the front wheel and tire.

   Tightening torque: 88.3 ~ 108 N·m

6. 6
   Loosen the guide pin bolt (B) and rotate the caliper body (A) upward so it does not interfere.

   

7. 7
   Remove the pad spring (D), pad retainers (C), and brake pads (B) from the caliper bracket (A).

   

8. 8
   Loosen the caliper mounting bolts (B) and remove the caliper bracket (A).

   Tightening Torque: 78.5 ~ 98 N·m

   

9. 9
   Remove the front brake disc by loosening the screws (A).

   Tightening Torque: 4.9 ~ 5.9 N·m

   

Replacement

1. 1
   Remove the front wheel and tire.
2. 2
   Loosen the guide pin bolt (B) and rotate the caliper body (A) upward so it does not interfere.

   

3. 3
   Replace the pad shim (D), pad retainers (C), and brake pads (B) in the caliper carrier (A).

   

4. 4
   Push the piston into the caliper body using SST (09581-11000).

   

5. 5
   Place the caliper body (A) on the caliper bracket and tighten the guide rod bolt (B).

   Tightening torque: 21.6 ~ 31 N·m

   

6. 6
   Install the front wheel and tire.

   Tightening torque: 88.3 ~ 108 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 and measure the disc thickness at 8 points, at least, at the same distance (5 mm) from the outer edge of the brake disc. Brake disc thickness Standard: 28 mm (1.10 in.) Service limit: 26.4 mm (1.04 in.) Runout: less than 0.005 mm (0.0002 in.)

   

4. 4
   If wear exceeds the allowable limit, replace the discs and pads as a set on both the left and right sides of the vehicle.
5. 5
   Check pad wear and, if the measured pad thickness is below the specified value, replace the pad assembly. Pad thickness Standard: 10.5 mm (0.413 in.) Service limit: 2.0 mm (0.0787 in.)

   

6. 6
   Make sure grease is applied to the sliding contact points, and inspect the abutment and metal backing for damage.
7. 7
   Position 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 (0.0016 in.) or less (new)

   

8. 8
   If brake disc runout exceeds the limit, replace the disc, then measure the runout again.
9. 9
   If runout does not exceed the limit, install the brake disc rotated 180°, then inspect the brake disc runout again.
10. 10
    If runout cannot be corrected by changing the brake disc position, replace the brake disc.

Installation

1. 1
   Install in the reverse order of removal.
2. 2
   Push the piston into the caliper body using SST (09581-11000).

   

   Do not strike the piston face with a hammer, and do not pry directly against the piston surface with a screwdriver to push the piston in. Insert a wooden block or used pad to protect the piston end. When retracting the piston, the entire piston face must be protected by the SST.

3. 3
   After installation, bleed the brake system. (Refer to Brake System Bleeding)
4. 4
   Install in the reverse order of removal.
5. 5
   Push the piston into the caliper body using SST (09581-11000).

   

   Do not strike the end of the piston with a hammer or pry directly against the piston surface with a screwdriver to push the piston back. Use a wooden block or used pad to protect the piston end. It is recommended to push the piston back using a piece of wood or a used pad. When retracting the piston, the entire piston face must be protected by the SST.