FE06-0010b

6.

Remove the brake caliper bracket bolts and remove the
brake caliper bracket.

Installation Procedure:

FE06-0011b

1.

Install the brake caliper bracket.

Torque: 105 Nm (Metric) 77.7 lb-ft (US English)

FE06-0012b

2.

Install the brake caliper brake hose inlet bolts.

Note

Rotate to install the brake caliper, install the bolt into
the  brake  caliper  inlet  to  prevent  damage  to  the
brake hose.

Torque: 16 Nm (Metric) 11.8 lb-ft (US English)

Brake System

Front Brake

6-13

FE06-0013b

3.

Install  the  brake  caliper  and  tighten  the  brake  caliper
upper assembly bolts.

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

4.

Install the brake pad.

5.

Install the front wheels.

6.

Lower the vehicle.

7.

Add clean brake fluid to the master cylinder to the required
level.

8.

Bleed air in the brake system. Refer to 

6.4.5.5

 

Hydraulic

Brake System Exhaust Procedure

.

Note

Left  and  right  front  brake  caliper  replacement  is
similar.

6.2.5.3 Brake Disc Replacement

Removal Procedure:

Warning!

Refer  to  "Vehicle  Lifting  Notice"  in  "Warnings  and
Notices".

FE06-0014b

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. Refer to 

6.2.5.2

 

Brake Caliper

Replacement - Front

.

Note

Remove the brake caliper without having to remove
the  brake  hose.  Using  a  wire  to  hang  the  brake
caliper in order to avoid damage to the brake hose.

5.

Remove the brake disc.

Note

Mark the location on the brake disc and the wheel
axle.

6-14

Front Brake

Brake System

6.

Check the front brake disc thickness if the thickness is less
than minimum, then replace the front brake disc.

Standard Thickness: 26.0 mm (1.02 in)
Minimum Thickness: 24.0 mm (0.98 in)

FE06-0016b

7.

Check the brake disc run out.

a. Install the front brake disc.

b. Use special tools and wheel nut to tighten the brake

disc.

Torque: 110 Nm (Metric) 81.4 lb-ft (US English)

c. Install  a  dial  indicator  on  the  shock  absorber,  away

from the wheel axle and the speed sensor.

Using the dial indicator to measure the brake disc run
out on the brake disc 13 mm (0.53 in) from the outer
edge.
Largest brake disc run out: 0.05 mm (0.0020 in)

Note

If the brake disc
If  the  run  out  is  more  than  maximum,  firstly
change  the  brake  disc  and  axle  installation
location  so  that  the  brake  disc  run  out  is  the
smallest.  if  after  changing  the  installation
location, the brake disc run out is still bigger than
the  maximum  value,  check  up  the  wheel  axle
bearing gap. if the bearing clearance and wheel
axle  hub  run  out  is  normal,  or  the  brake  disc
thickness is within the specified limits, grind the
brake disc. if the brake disc thickness is less than
the minimum, replace the brake disc.

Installation Procedure:

FE06-0017b

1.

Align the brake disc and the wheel axle mark, install the
brake disc.

2.

Install the brake caliper.

3.

Install the brake pad.

4.

Install the front wheels.

5.

Lower the vehicle.

Note

The  left  and  right  front  brake  disc  replacement  is
similar.

Brake System

Front Brake

6-15

6.2.5.4 Disc Brake Dust Cover Replacement

Removal Procedure:

Warning!

Refer  to  "Vehicle  Lifting  Notice"  in  "Warnings  and
Notices".

FE06-0018b

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

.

Note

Refer  to  "Brake  Caliper  Notice"  in  "Warnings  and
Notices".

4.

Remove the brake caliper. Refer to 

6.2.5.2

 

Brake Caliper

Replacement - Front

.

Note

Remove the brake caliper without having to remove
the brake hose. Using a wire to support the brake
caliper to avoid damage to the brake hose.

5.

Remove  the  brake  disc.  Refer  to 

6.2.5.3

 

Brake  Disc

Replacement

.

6.

Remove  the  disc  brake  dust  cover  retaining  bolts  and
remove the disc brake dust cover.

6-16

Front Brake

Brake System