Front

REMOVAL

HINT:
- Use the same procedures for the RH side and LH side.
- The procedures listed below are for the LH side.

1. Remove front wheel
2. Drain brake fluid
(a) Draw out fluid with syringe.

Notice: Wash brake fluid off immediately if it adheres to any painted surfaces.





3. Remove front disc brake anti-rattle with hole pin
(a) Remove the pin hold clip.

Notice: The pin hold clip can be used again if it has sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt foreign particles cleaned off.

(b) Remove the front disc brake anti-rattle with hole pin while pushing on the anti-rattle spring.

4. Remove front disc brake anti-rattle spring

Notice: The anti-rattle spring can be used again if it has sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt foreign particles cleaned off.

5. Remove disc brake pad kit front (pad only)
(a) Remove the 2 pads and the 2 anti-squeal shims from each pad.





6. Disconnect front brake flexible hose
(a) Remove the union bolt and gasket from the disc brake cylinder, and then disconnect the front brake flexible hose from the disc brake cylinder.




7. Remove disc brake cylinder assembly
(a) Remove the 2 bolts and disc brake cylinder from the knuckle.

DISASSEMBLY




1. Remove cylinder boot
(a) Using a screwdriver, remove the 4 cylinder boots from the disc brake cylinder.




2. Remove front disc brake piston
(a) Prepare a wooden plate to hold the pistons.




(b) Place the plate between the pistons and insert a pad into one side.
(c) Use compressed air to remove the pistons alternately from the disc brake cylinder.

Caution: Do not place your fingers in front of the pistons when using compressed air.





3. Remove piston seal
(a) Using a screwdriver, remove the 4 piston seals from the disc brake cylinder.

4. Remove front disc brake bleeder plug
(a) Remove the front disc brake bleeder plug from the disc brake cylinder.




5. Remove front disc
(a) Put matchmarks on the front disc and the axle hub.
(b) Remove the front disc.


INSPECTION




1. Inspect pad lining thickness
(a) Using a ruler, measure the pad lining thickness.
Standard 12.5 mm (0.492 in)
Minimum 1.0 mm (0.039 in)
(b) If the pad lining thickness is less than the minimum, replace the pad.





2. Inspect disc thickness
(a) Using a micrometer, measure the disc thickness.
Standard 30.0 mm (1.181 in)
Minimum 27.0 mm (1.063 in)
(b) If the disc thickness is minimum or less, replace the disc.

3. Inspect brake cylinder piston
(a) Check the cylinder bore and piston for rust or scoring. If necessary replace the disc brake cylinder assembly.




4. Inspect disc runout
(a) Tighten the disc with the 3 hub nuts.
Service Tool: 09330-0021
Torque 103 Nm (76 ft lbs)




(b) Using a dial indicator, measure the disc runout 10 mm (0.39 in) inside the outer edge of the disc.
Maximum runout 0.05mm (00.20 in)
(c) If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maximum even when the installation positions are changed, check the bearing play in the axial direction and the axle hub runout are normal and if the disc thickness is not within the specified range, shave the disc. If the disc thickness is less than the minimum, replace the disc.
(d) Remove the front disc.

REASSEMBLY

1. Install front disc
(a) Align the matchmarks, and then install the front disc.

HINT: When replacing the disc with a new one, select the installation position where the front disc has the minimum runout.

2. Temporarily tighten front disc brake bleeder plug
(a) Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder.

3. Install piston seal
(a) Apply lithium soap base glycol grease to 4 new piston seals.



(b) Install the 4 piston seals to the disc brake cylinder.

4. Install front disc brake piston
(a) Apply lithium soap base glycol to the front disc brake pistons and 4 new cylinder boots.
(b) Install the 4 cylinder boots to the 4 front disc brake pistons.



(c) Install the 4 pistons to the front disc brake cylinder.
Notice: Do not install the pistons forcibly in the disc brake cylinder.




5. Install cylinder boot
(a) Install the 4 cylinder boots to the front disc brake cylinder.
Notice: Install the boot securely to the grooves of the cylinder and piston, and take care not to damage the cylinder boot.

INSTALLATION




1. Install disc brake cylinder assembly
(a) Install the caliper with the 2 bolts.
Torque 78.4 Nm (58 ft lbs)




2. Connect front flexible hose
(a) Connect the flexible hose with union bolt and a new gasket.
Torque 39 Nm (29 ft lbs)

Notice: Install the flexible hose lock securely in the lock hole in the disc brake cylinder assembly.




3. Install disc brake pad kit front (pad only)
HINT: Install the clip lock securely in the groove of the pad.

(a) Apply disc brake grease to the anti-squeal shims and install them to each pad.

Notice:
- When replace worn pads, the anti-squeal shims must be replaced together with the pad.
- Install each shim in the correct position and direction.
- There should be no oil or grease on the friction surface of the pads and the disc.




4. Install front disc brake anti-rattle spring
(a) Install the hole pin while pushing on teh front disc brake anti-rattle spring.
(b) Install the clip.

5. Install front disc brake with hole pin
6. Disable brake control
7. Add reservoir with brake fluid
8. Bleed front brake system
9. Check brake fluid level
10. Inspect brake fluid leakage
11. Install front wheel
12. Check and clear DTCs