FE06-0016b

1. Remove the brake disc from the vehicle. Refer to 

6.2.5.3

 

Brake Disc Replacement

and / or

6.3.5.3

 

Brake Disc Replacement -

Rear

.

2. Clean the brake disc friction surface with industrial alcohol or similar cleaning agent .

3. Install the brake disc to the wheel brake disc / axle flange.

4. Manually install the nuts and tighten the nuts with a wrench.

5. Install the dial indicator base to the steering knuckle and place the dial indicator measuring head, so that it contacts with the

brake disc friction surface and is at 90 °, and is from the brake disc outer edge about 13 mm (Metric) 0.5 in (US English)

6. Rotate the brake disc, until the dial indicator reading reaches the minimum, and then dial the indicator to zero.

7. Rotate the brake disc, until the dial indicator reading reaches the maximum.

8. Mark and record the face run out.

9. After install the brake disc assembly, compare the face run out with the specifications.

Standard Value: 0.05 mm (Metric) 0.002 in (US English)

10. If the brake disc assembly rear face run out exceeds the specifications after installation, check the bearing axial clearance and

the wheel axle run out. If the bearing axial clearance and the wheel axle run out is normal, and brake disc thickness is within the
prescribed limits, adjust the brake disc surface in order to ensure proper flatness.

Brake System

Front Brake

6-9

6.2.5 Removal and Installation
6.2.5.1 Brake Pad Replacement - Front

Removal Procedure:

Warning!

Refer  to  'Vehicle  Lifting  Warning"  in  "Warnings  and
Notices".
Refer  to  "Brake  Dust  Warning"  in  "Warnings  and
Notices".

FE06-0003b

1.

Lift and support the vehicle. Refer to

1.3

 

Lifting and Jacking

the Vehicle

.

Note

In order to maintain wheel balance, before the tire
removal, mark the tire relative to the wheel position.

2.

Remove  the  front  wheel.  Refer  to 

4.4.5.1

 

Wheel

Replacement

.

3.

Remove brake caliper lower assembly bolts.

FE06-0004b

4.

Flip the caliper upward.

5.

Remove the brake pad.

6-10

Front Brake

Brake System

FE06-0005b

6.

Check the brake pad.

Standard Thickness: 11.0 mm (0.433 in)
Minimum Thickness: 2.0 mm (0.078 in)

Note

If  the  brake  pad  lining  thickness  is  less  than  the
minimum value, replace the front brake pad.

Installation Procedure:

FE06-0006b

1.

Check the brake pad lining thickness.

2.

Install the brake pad into the caliper.

FE06-0007b

3.

When necessary, use a dedicated tool to push the piston
inside.

Note

Carefully drop down the brake caliper assembly and
install the lower assembly bolts, do not damage the
piston dust seals.

4.

Install the bolt assembly the bolt assembly to the bottom
of the drop-down brake caliper and .

Torque: 30 Nm (Metric) 22.2 lb-ft (US English)

5.

Align  the  marks  made  when  removing  the  wheels  and
install the front wheels.

6.

Lower the vehicle.

Note

The  left  and  right  front  brake  pad  replacement  is
similar.

Brake System

Front Brake

6-11

6.2.5.2 Brake Caliper Replacement - Front

Removal Procedure:

Warning!

Refer  to  'Vehicle  Lifting  Warning"  in  "Warnings  and
Notices".
Refer  to  "Brake  Fluid  Effects  on  Paint  and  Electrical
Components Notice in "Warnings and Notices".

FE06-0008b

1.

Lift and support the vehicle. Refer to

1.3

 

Lifting and Jacking

the Vehicle

.

Note

In order to maintain wheel balance, before the tire
removal, mark the tire relative to the wheel position.

2.

Remove  the  front  wheels.  Refer  to 

4.4.5.1

 

Wheel

Replacement

.

3.

Remove  the  brake  pad.  Refer  to 

6.2.5.1

 

Brake  Pad

Replacement - Front

.

4.

Remove  the  brake  caliper  upper  assembly  bolts  and
remove the brake caliper.

FE06-0009b

5.

Remove the brake caliper brake hose inlet retaining bolts,
remove  the  brake  caliper.  Plug  the  brake  caliper  inlet
brake  hose  to  prevent  the  brake  fluid  loss  or
contamination.

Note

Rotate  to  remove  the  brake  caliper,  separate  the
brake  hose  import  bolt  from  brake  caliper  inlet  to
prevent damage to the brake hose.

6-12

Front Brake

Brake System