Brake Pad: Service and Repair

REPLACEMENT
1. Remove front wheel.
Remove the wheel and temporarily fasten the disc with the hub nuts.





2. Inspect pad lining thickness.
Check the pad thickness through the caliper inspection hole and replace the pads if they are not within the specification.
Minimum thickness: 1.0 mm (0.039 inch)





3. Lift up caliper.
a. Remove the flexible hose from the shock absorber bracket.
b. Hold the sliding pin on the bottom and loosen the installation bolt.
c. Remove the installation bolt.
d. Lift up the caliper and suspend it securely.

HINT: Do not disconnect the flexible hose from the caliper.

4. Remove these parts:
- 2 brake pads
- 4 anti-squeal shims
- 4 pad support plates

NOTICE: The support plates can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off.

5. Check disc thickness and runout.





a. Measure disc thickness.
Using a micrometer, measure the disc thickness.
Standard thickness: 18.0 mm (0.709 inch)
Minimum thickness: 16.0 mm (0.630 inch)
Replace the disc if the thickness of the disc is at the minimum thickness or less. Replace the disc or grind it on a lathe if it is scored or is worn unevenly.





b. Measure disc runout.
Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the outside edge.
Maximum disc runout: 0.05 mm (0.0020 inch)
If the disc's runout is at the maximum value or greater, check the bearing play in the axial direction and check the axle hub runout. (See "Steering and Suspension") If the bearing play and axle hub runout are not abnormal, adjust the disc runout or grind it on an "On-Car" brake lathe.
6. Install 4 pad support plates.
7. Install new pads.

NOTICE: When replacing worn pads, the anti-squeal shims must be replaced together with the pads.





a. Apply disc brake grease to both side of the inner anti squeal shims.
b. Install the anti-squeal shim to the inner pad.
c. Install the inner pad with pad wear indicator plate facing upward.
d. Install the outer pad.

NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc.





8. Install caliper.
a. Draw out a small amount of brake fluid from the reservoir.
b. Press in the piston with a hammer handle or an equivalent.

HINT: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape.

c. Install the caliper.
d. Hold the sliding pin and torque the installation bolt.
Torque: 26 Nm (20 ft. lbs.)
e. Install the flexible hose bracket.
Torque: 33 Nm (25 ft. lbs.)
9. Install front wheel.
10. Check that fluid level is at max line.