Front

Front Brake Pad Replacement

CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
^ Avoid breathing dust particles.
^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

Replacement





1. For '04-05 models, remove the brake hose bracket mounting bolt (A).
2. Remove the flange bolt (B).





3. Pivot the caliper up out of the way, and remove the brake pads (A).
4. Remove the pad shim(s) (B).
5. Check the hose and pin boots for damage and deterioration.





6. Remove the pad retainers (A), and check the caliper pins for free movement.
7. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.
8. Check the brake disc for damage and cracks.
9. Install the pad retainers.





10. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to brake pad sides of the pad shims (A), the back of the brake pads (B), and the other areas indicated by the arrows. Wipe excess assembly paste off the shim. Contaminated brake discs and brake pads reduce stopping ability. Keep grease and paste off the brake discs and brake pads.
11. Install the brake pads and pad shims correctly. Install the brake pads with the wear indicators (C) on the lower brake inside. If you are reusing the brake pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency.





12. Push in the piston (A) so the caliper will fit over the brake pads. Check the brake fluid level. The brake fluid may overflow if the reservoir is too full. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down.





13. Pivot the caliper (A) down into position. Be careful not to damage the pin boots, install the flange bolt (B), and tighten it to the specified torque.
14. For '04-05 models, install the brake hose bracket mounting bolt (C), and tighten it to the specified torque.
15. Press the brake pedal several times to make sure the brakes work, then test-drive.

NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads has been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke.

16. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.