Removal
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)
Remove the brake hose mounting bracket. (Knuckle mounting part : D)
Loosen the hose eye-bolt (B) and caliper mounting bolts (C), then remove the front caliper assembly (A).
Tightening torque
Brake hose to caliper:
24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7 lb-ft)
Caliper assembly to knuckle:
78.5 - 98.1 N.m (8.0 - 10.0 kgf.m, 57.9 - 72.3 lb-ft)
Remove the front brake disc by loosening the screws.
Replacement
Remove one side locking pin (A). Push the retraction spring (C) and extract the guide pin (B).
Remove other side locking pin (D), guide pin (E) and retraction spring (C).
Remove the pad shim and pad.
CAUTION:
Do not step on a brake pedal.
Inspection
Front Brake Disc Thickness Check
Check the brake pads for wear and fade.
Check the brake disc for damage and cracks.
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
Standard: 30mm (1.181in)
Service limit: 28.4mm (1.118in)
Deviation: Less than 0.005mm (0.0002in)
If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
Front Brake Pad Check
Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.
Pad thickness
Standard value: 10.5 mm (0.413 in)
Service limit: 2.0 mm (0.079 in)
Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
Front Brake Disc Runout Check
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: 0.03 mm (0.0012 in.) or less (new one)
If the runout of the brake disc exceeds the limit specification, reinstall the disc after turning the disc 72°clockwise. Recheck the runout. If the runout exceeds the specification, try turning the disc by 72°and recheck the runout until a full revolution(360°, 4 steps).
If the runout cannot be corrected by turning the disc, replace the brake disc.
When installing brake disc, runout peak point markings (A) on disc and hub must be as close as possible (within 72°range).
After installing the new disc repeat above procedure 1 - 4 again.
Installation
Installation is the reverse of removal.
Use a SST (09581-11000) when installing the brake caliper assembly.
After installation, bleed the brake system.
Hope this helps!
