Front Disc Brake

FRONT DISC BRAKE PAD CHECK AND REPLACEMENT





NOTE: The brake pads have wear indicators that contact the brake disc when the brake pad thickness becomes 2 mm (0.08 inch).
The wear indicators emit a squealing sound to warn the driver to have the pads replaced and to have the brake system checked.





1. Check brake pad thickness through caliper body check port.
Standard value: 10 mm (0.39 inch)
Limit: 2.0 mm (0.08 inch)

CAUTION: When the limit is exceeded, the brake pads on both the left and right wheels must be replaced as a set.

CAUTION: If there is a significant difference in the thickness of the pads on the left and right sides, check the sliding condition of the piston, lock pin and guide pin.





2. Remove guide pin. Lift caliper assembly upwards and support it with wires

CAUTION: Do not contaminate or wipe off the special grease that is on the guide pin.





3. Remove the following parts from caliper support.
1. Pad & wear indicator assembly
2. Pad assembly
3. Clip
4. Outer shim





4. Take out the drive shaft.
5. Set the special tool to the front hub assembly as shown in the illustration





6. Measure hub torque (A) with pads removed to measure brake drag torque. Torque value will be used later to calculate brake drag force with the pads installed.

NOTE: Tighten the nuts in order to secure the disc to the hub.

7. Fit the pad clip and pads to the caliper support.





8. Clean pistons and push into cylinder (caliper) with special tool.
9. Be careful that the piston boot does not catch and tear as the caliper assembly and lock pin are installed.





10. Check brake drag torque as follows.
1. Start engine and hold brake pedal down for 5 seconds. [Pedal depression force: approx. 196 N (44 lbs.)]
2. Stop engine.
3. Turn brake disc forward 10 times.
4. Check hub torque (B) with spring scale.
5. Calculate the drag torque of the disc brake [difference between hub torque (B) and hub torque (A)].
Standard value: 69 N (15.4 lbs.) [4 Nm (35 inch lbs.)] or less
11. If the difference between brake drag torque and hub torque exceeds the standard value, disassemble piston and clean the piston. Check for corrosion or worn piston seal, and check the sliding condition of the lock pin and guide pin.
12. Reinstall the drive shaft.