Removal and Installation

FRONT DISC BRAKE:

Pad Replacement

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.
Burnish the brake contact surfaces after refinishing or replacing drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage.


1. Remove reservoir cap.





2. Remove lower main pin bolt.





3. Rotate cylinder body upward. Remove pad retainers, inner and outer shims and shim cover (if equipped).


Standard pad thickness:....................10 mm (0.39 inch)
Pad wear limit:......................2.0 mm (0.079 inch)

CAUTION: Carefully monitor brake fluid level because brake fluid will return to reservoir tank when pushing back pistons.



Caliper / REMOVAL

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.

NOTE: 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.


INSTALLATION

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






1. Install caliper assembly.

Torque member fixing bolts
KA24DE models:.....................72 - 97 Nm (7.3 - 9.9 kgf-cm, 53 - 72 ft. lbs.)
VG33E and VG33ER models:......................133 - 177 Nm (14 - 18 kgf-cm, 101 - 130 ft. lbs.)

2. Install brake hose to caliper securely.

Connecting bolt:................17 - 20 Nm (1.8 - 2.0 kgf-cm, 13 - 14 ft. lbs.)

3. Bleed air.