Front Disc Brake Disc with Standard Brakes

Brake Disc

Removal

WARNING: If installing a new brake disc, install new brake pads.

CAUTION: Brake discs must be renewed in pairs.

NOTE:
LH illustration shown, RH is similar.

NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.

NOTE:
The brake pad wear warning indicator sensor must be replaced each time the brake pads are serviced.
1
WARNING: Make sure to support the vehicle with axle stands.
Raise and support the vehicle.
2 Remove the front wheel and tire.




3
CAUTION: The brake pad wear indicator sensor is easily damaged. Do not use a lever to remove the sensor. Use fingers only.
LH side front: Disconnect the brake pad wear indicator sensor wiring harness.




4
NOTE:
Use an additional wrench to prevent the component from rotating.
Remove the brake caliper lower bolt.




5
NOTE:
Note the orientation of the brake pads.
Remove the brake pads.
- Rotate the brake caliper upwards.
- Remove the 2 clips.




6
CAUTION: Do not allow the brake caliper to hang on the brake hose.
Remove the brake caliper.
- Remove the brake caliper anchor bolts.
- Tie the brake caliper aside.




7 Remove the front brake disc.
- Remove the Allen screw.

Installation
1 Make sure the brake disc and hub mating surfaces are clean.
2 Install the brake disc.
- Tighten the Allen screw to 16 Nm (12 lb.ft).
3 Install the brake caliper.
- Clean the component mating faces.
- Tighten the bolts to 275 Nm (203 lb.ft).
4
WARNING: Do not use compressed air to clean brake components. Dust from friction materials can be harmful if inhaled.
Clean the brake caliper housing and anchor plate using brake cleaning fluid.
5 Inspect the caliper piston and slide pin seals for damage.
6
CAUTION: The brake caliper should move freely on both slide pins.
CAUTION: If necessary, renew the components.
Check the slide pins for correct operation.
7 Position a bleed jar containing a small quantity of approved brake fluid. Connect the bleed tube to the bleed screw and loosen the screw.
8 Press the pistons into the caliper housing.
- Tighten the bleed screw to 10 Nm (7 lb.ft).
9 Disconnect the bleed tube and remove the jar.

10
NOTE:
Make sure the brake pads are installed in the correct orientation.
Install the brake pads.
- Install the 2 clips.
- Apply a suitable amount of the supplied grease to the mating faces of the brake pads and brake calipers.

11 Rotate the brake caliper downwards.
- Tighten the bolt to 32 Nm (24 lb.ft).

12 LH side front: Connect the brake pad wear indicator wiring harness.

13 Install the wheel and tire.
- Tighten the wheel nuts to 140 Nm (103 lb.ft).

14 Depress the brake pedal several times, check the fluid level in the brake fluid reservoir and top-up with brake fluid if necessary.