Brake Pad: Service and Repair

Front Inspection and Replacement

CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
^ Avoid breathing dust particles.
^ Never use an air hose or brush to clean brake assemblies. Use an OHSA-Approved vacuum cleaner.

NOTICE: To avoid damage, do not strike aluminum parts with a metal hammer. If necessary, tap gently with a plastic tipped hammer.

NOTE: Nuts and bolts with the [star] mark are special corrosion-resistant Dacro fasteners. Use the same type if replacement is necessary.

Replacement





1. Remove the brake hose bracket mounting bolts (A) from the damper.
2. Remove the bolt (B) and pivot the caliper (C) up out of the way. Check the hose, pin boot, and sleeve boots for damage and deterioration.





3. Remove the pad shim (A), pad retainers (B), and inner (C) and outer (D) pad.
4. Clean the caliper thoroughly; the caliper is aluminum, check for cracks.
5. Check the brake disc for damage and cracks.





6. Install the pad retainers (A).





7. Apply Dow Corning Molykote M77 grease to both sides of the pad shim (A), the back of the pads (B) and other areas indicated by the arrows. Wipe excess grease off the shim. Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
8. Install the brake pads and pad shim correctly. Install the pad with the wear indicator (C) on the inside. If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency.





9. Push in the piston (A) so the caliper will fit over the pads. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down.
10. Pivot the caliper down into position. Being careful not to damage the pin boot, install the bolt (B), and tighten it to the specified torque.
11. Install the brake hose bracket onto the damper.
12. Press the brake pedal several times to make sure the brakes work, then test-drive.

NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke.

13. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.