Front

FRONT DISC BRAKE





LUBRICATION POINTS

REPLACEMENT
INSPECTION AND REPLACEMENT OF FRONT DISC BRAKE PADS





1. Check the brake pad thickness through the caliper body inspection hole.

CAUTION:
1. If the pad lining thickness is out of specification, left and right pads must be replaced as a complete set.
2. When the thickness difference between the left pad and the right pad is large, check the sliding condition of the piston, the lock pin and the guide pin.





2. Remove the guide pin, lift the caliper assembly up and suspend it with a wire.

CAUTION: Be careful not to contaminate the lock pin and the guide pin with grease.








3. Remove the following parts from the caliper support.
1. Pad and wear sensor assembly
2. Pad assembly
3. Clip
4. Outer shim

INSPECTION
FRONT BRAKE DISC THICKNESS CHECK
1. Using a caliper, measure nominal disc thickness at eight positions, approximately 45° apart and 10 mm (0.39 inch) from the outer edge of the disc.
Brake disc thickness
Standard value: 26 mm (1.02 inch)
Limit: 24.4 mm (0.96 inch)
Thickness variation (at least 8 positions)
2. Wherever you measure the thickness value use a micrometer. The pad must be less than 0.005 mm in the direction of the circumference and less than 0.05mm in the direction of radius.





3. If the disc is beyond the limits for thickness or unevenness remove it and install a new one.

FRONT BRAKE DISC RUN-OUT CHECK





1. Remove the caliper support, then raise the caliper assembly upward and suspend with wire.

NOTE: Tighten the nuts in order to mount the disc to the hub.





2. Place a dial gauge about 5 mm (0.2 inch) from the outer circumference of the brake disc, and measure the runout of the disc.
Limit: 0.04 mm (0.0016 inch)

FRONT BRAKE DISC RUN OUT CORRECTION
1. If the run out of the brake disc is equivalent to or exceeds the limit specification, replace the disc and hub, and then measure the run out again.





1) Before removing the brake disc, chalk both sides of the wheel stud on the side at which the run out is greatest.





2) Remove the brake disc, and then place a dial gauge as shown in the illustration; then move the hub in the axial direction and measure the run out.
Limit: 0.05 mm (0.0020 inch)
If it is equivalent to or exceeds the limit, disassemble the hub knuckle and check each part.





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

INSTALLATION
1. Install the pad clips.
2. Install the pads on each pad clip.

NOTE:
1. All four pads must be replaced as a complete set.
2. When replacing the brake pads, check for deformation. When replacing the guide spring, use a new one or thoroughly clean the used one.

3. Press in the piston with a hammer handle or the special tool.
4. Lower and insert the brake cylinder carefully so as not to damage the boot.





5. Tighten the two guide rod bolts to the specified torque.
Guide rod bolt: 22 - 32 Nm (220 - 320 kgf-cm, 16.2 - 23.6 ft. lbs.)

DISASSEMBLY
Front disc brakes should be disassembled separately. Do not mix right-hand and left-hand parts.





1. Remove the piston boot/piston.
Blow compressed air into the brake hose seating hole. Remove the piston and the piston boot.

CAUTION: Remove the piston using a plastic hammer handle. Blow air slowly adjusting the heights of the two pistons to push them out equally.
The secondary piston should not be removed before the primary piston is removed completely. Otherwise the secondary piston can't be removed.

2. Remove the piston seal.
1) Remove the piston seal with your finger.

CAUTION: Do not use a screwdriver or another tool because it may damage the cylinder.





2) Clean the piston surface and cylinder using the alcohol or the specified brake fluid.
Brake fluid: DOT 3 or DOT 4

INSPECTION
1. Check the cylinder for wear, damage and rust.
2. Check the piston surface for wear, damage and rust.
3. Check the caliper body and sleeve for wear.
4. Check that grease is applied, and the pad and backing metal are not damaged.





5. Check the pad wear. Measure the pad thickness and replace it if it is less than the specified value.
Pad thickness
Specification: 10.0 mm (0.39 inch)
Service limit: 2.0 mm (0.08 inch)

REASSEMBLY
1. Clean all components with isopropyl alcohol except for the pad and shim.
2. Install the piston seal.
3. After applying the specified brake fluid to the piston outer surface, install the piston into the cylinder.





4. Install the piston boot and boot ring.





5. Install the guide pin boots and guide pin.

INSTALLATION
1. Install the pads and brake cylinder.
2. Install the brake hose to the caliper.
Bleeder screw tightening torque: 7 - 9 Nm (70 - 90 kgf-cm, 5.2 - 6.6 ft. lbs.)
3. Fill the brake reservoir with brake fluid.





4. Bleed the system.