Disc Brake Service

WARNING: CLEAN BRAKES WITH A VACUUM DUST COLLECTOR TO MINIMIZE THE HAZARD OF AIRBORNE PARTICLES OR OTHER MATERIALS.

CAUTION:
- When cylinder body is open, do not depress brake pedal, or piston will pop out.
- Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing pads.
- If shims are rusted or show peeling of the rubber coat, replace them with new shims.
- It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose.
- Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.

REPLACEMENT

Pads

1. Remove master cylinder reservoir cap.





2. Remove lower pin bolt.





3. Open cylinder body upward. Then remove pad retainers, and inner and outer shims.
Standard pad thickness: 11.0 mm (0.433 inch)
Pad wear limit: 2.0 mm (0.079 inch)

NOTE: Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.

REMOVAL

Caliper

WARNING: CLEAN BRAKE PADS WITH A VACUUM DUST COLLECTOR TO MINIMIZE THE HAZARD OF AIRBORNE PARTICLES OR OTHER MATERIALS.

CAUTION: Suspend caliper assembly with wire so as not to stretch brake hose.





- Remove torque member fixing bolts and connecting bolt. It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend caliper assembly with wire so as not to stretch brake hose.

DISASSEMBLY

Caliper

WARNING: DO NOT PLACE YOUR FINGERS IN FRONT OF PISTON.

CAUTION: Do not scratch or score cylinder wall.





1. Push out piston with dust seal with compressed air.
2. Remove piston seal with a suitable tool.

INSPECTION

Caliper

Cylinder Body
- Check inside surface of cylinder for score, rust, wear, damage and presence of foreign objects. If any of the above conditions are observed, replace cylinder body.
- Minor damage from rust or foreign objects may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.

CAUTION: Use brake fluid to clean. Never use mineral oil.

Piston
- Check piston for score, rust, wear, damage and presence of foreign objects. Replace if any of the above conditions are observed.

CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign objects are stuck to sliding surface.

Slide Pin, Pin Bolt and Pin Boot
- Check for wear, cracks, rust and other damage. Replace if any of the above conditions are observed.

Rotor

Runout
1. Secure rotor to wheel hub with at least two M12 x 1.25 nuts.





2. Check runout using a dial indicator.
Maximum runout: 0.1 mm (0.004 inch)
Axial end play: 0.0 mm (0.0 inch)

NOTE: Make sure that wheel bearing axial end play is within the specifications before measuring.

3. If the runout is out of specification, find minimum runout position as follows:
a. Remove nuts and rotor from wheel hub.
b. Shift the rotor one hole and secure rotor to wheel hub with nuts.
c. Measure runout.
d. Repeat steps a. to c. so that minimum runout position can be found.
4. If the runout is still out of specification, turn rotor with on-car brake lathe ("MAD, DL-8700", "AMMCO 700 and 705", or equivalent).

Thickness





- Check thickness variation in at least 8 places.
Maximum variation: 0.015 mm (0.0006 in)

- If thickness variation exceeds the specification, turn rotor with on-car brake lathe.
Minimum disc thickness: 26 mm (1.024 in)

ASSEMBLY

Caliper





1. Insert piston seal into groove on cylinder body.
2. With piston boot fitted to piston, insert piston boot into groove on cylinder body and install piston.
3. Properly secure piston boot.

INSTALLATION

Caliper

CAUTION:
- Refill with new brake fluid "DOT 3".
- Never reuse drained brake fluid.

1. Install caliper assembly.





2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
4. Bleed air. Refer to Brake Bleeding / Bleeding Brake System.