Repair Procedures

Removal

General caliper type
1. Remove the front wheel & tire.

Tightening torque :
88.3 - 107.9 N.m (9.0 - 11.0 kgf.m, 65.1 - 79.6 lb-ft)

2. Loosen the hose eye-bolt (B) and caliper mounting bolts (C), then remove the front caliper assembly (A).

Tightening torque
Brake hose to caliper (B):
24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7 lb-ft)
Caliper assembly to knuckle (C):
78.5 - 98.1 N.m (8.0 - 10.0 kgf.m, 57.9 - 72.3 lb-ft)




3. Remove the front brake disc by loosening the screws.





Brembo caliper type
1. Remove the front wheel & tire.

Tightening torque :
88.3 - 107.9 N.m (9.0 - 11.0 kgf.m, 65.1 - 79.6 lb-ft)

2. Loosen the hose eye-bolt (B) and caliper mounting bolts (C), then remove the front caliper assembly (A).

Tightening torque
Brake hose to caliper (B):
24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7 lb-ft)
Caliper assembly to knuckle (C):
88.3 - 103.0 N.m (9.0 - 10.5 kgf.m, 65.1 - 75.9 lb-ft)




3. Remove the front brake disc by loosening the screws.






Replacement

Front Brake Pads (General caliper type)
1. Remove the brake hose mounting bracket (knuckle mounting part : D).




2. Loosen the guide rod bolt (B) and remove the caliper body (A).

Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)




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





Front Brake Pads (Brembo caliper type)
1. Remove the guide pin (B) of the lower part with the pin punch (A).




2. Remove the guide pin (C) of the upper part and retraction spring (D).




3. Replace brake pads (E) at the caliper body.






Inspection

Front Brake Disc Thickness Check
1. Check the brake pads for wear and fade.
2. Check the brake disc for damage and cracks.
3. Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm) from the brake disc outer circle.

Brake disc thickness
General caliper type
Standard: 28mm (1.10in)
Service limit: 26.4mm (1.04in)
Deviation: Less than 0.005mm (0.0002in) - circumference
Less than 0.01mm (0.0004in) - radius
Brembo caliper type
Standard: 28mm (1.10in)
Service limit: 26mm (1.02in)
Deviation: Less than 0.01mm (0.0004in) - circumference
Less than 0.04mm (0.0016in) - radius




4. If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.

Front Brake Pad Check
1. Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.

Pad thickness
General caliper type
Standard value : 11mm (0.43in)
Service limit : 2.0mm (0.0787in)
Brembo caliper type
Standard value : 8.5mm (0.33in)
Service limit : 2.0mm (0.0787in)

2. Check that grease is applied, to sliding contact points and the pad and backing metal for damage.

Front Brake Disc Runout Check
1. Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.

Brake disc runout
Limit : 0.035mm (0.00137in.) or less (new one)




2. If the run out of the brake disc exceeds the limit specification, replace the disc, and then measure the run out again.
3. If the run out does not exceed the limit specification, install the brake disc after turning it and then check the run out of the brake disc again.
4. If the run out cannot be corrected by changing the position of the brake disc, replace the brake disc.

Installation

1. Installation is the reverse of removal.
2. Use a SST (09581-11000) when installing the brake caliper assembly.
3. After installation, bleed the brake system.