Front
BRAKE PAD: Removal and InstallationBR-33 Exploded View:
REMOVAL
WARNING:
Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with compressed air.
CAUTION:
^ Never depress the brake pedal while removing the brake pads because the piston may pop out.
^ Never spill or splash brake fluid on the disc rotor.
1. Remove tires with power tool.
2. Remove lower sliding pin bolt.
3. Suspend the cylinder body with suitable wire so that the brake hose will not stretch. Then remove the brake pads, shims, shim covers and pad retainers from the torque member.
CAUTION:
^ Never deform the pad retainer when removing the pad retainer from the torque member.
^ Never damage the piston boot.
^ Never drop the brake pads, shims, and the shim covers.
INSTALLATION
WARNING:
Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with compressed air.
CAUTION:
^ Never depress the brake pedal while removing the brake pads or the cylinder body because the piston may pop out.
^ Never spill or splash brake fluid on the disc rotor.
1. Apply Copper based brake grease to the pad retainers before installing it to the torque member if the pad retainers has been removed.
CAUTION:
^ Securely assemble the pad retainers so that it will not be lifted up from the torque member.
^ Never deform the pad retainers.
2. Apply Copper based brake grease to the mating faces between the shims and the shim covers and install them to the brake pad.
CAUTION:
Always replace the shims together with the shim covers when replacing the brake pad.
3. Install the brake pads to the torque member.
CAUTION:
Both inner and outer pads have a pad return system on the pad retainer. Install pad return lever (1) securely to pad wear sensor (2).
4. Install cylinder body to torque member.
CAUTION:
^ Never damage the piston boot.
^ When replacing brake pad with new one, check a brake fluid level in the reservoir tank because brake fluid returns to master cylinder reservoir tank when pressing piston in.
NOTE:
^ Use a disc brake piston tool to easily press piston.
5. Install the lower sliding pin bolt and tighten it to the specified torque.
6. Depress the brake pedal several times to check that no drag feel is present for the front disc brake. Refer to "BRAKE PAD: Inspection".
BRAKE PAD: Inspection
INSPECTION AFTER REMOVAL
Replace the shims and the shim covers if rust is excessively attached.
INSPECTION AFTER INSTALLATION
1. Check a drag of front disc brake. If any drag is found, follow the procedure described below.
2. Remove brake pads.
3. Press the pistons.
CAUTION:
^ Never damage the piston boot.
^ When replacing a pad with new one, check a brake fluid level in the reservoir tank because brake fluid returns to master cylinder reservoir tank when pressing piston in.
NOTE:
Use a disc brake piston tool to easily press piston.
4. Install brake pads.
5. Depress the brake pedal several times.
6. Check a drag of front disc brake again. If any drag is found, disassemble the cylinder body.
7. Burnish contact surfaces after refinishing or replacing brake pads, or if a soft pedal occurs at very low mileage. Refer to BR-14, "BRAKE PAD: Inspection and Adjustment". Front