Front Brake Pad Inspection and Replacement
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 appropriate vacuum cleaner.

Inspection
  1. Remove the front wheels.
  1. Check the thickness (A) of the inner pad (B) and outer pad (C). Do not include the thickness of the backing plate.
    Brake pad thickness:
    Standard:
    11.0 mm (0.43 in.)
    Service limit:
    1.6 mm (0.06 in.)

  1. If the brake pad thickness is less than the service limit, replace the front brake pads as a set.
Inner pad
Outer pad
Replacement
  1. Remove the front wheel.
  1. Remove the flange bolt (A) while holding the caliper pin (B) with a wrench. Be careful not to damage the pin boot, and pivot the caliper (C) up out of the way. Check the hose and pin boots for damage and deterioration.
  1. Remove the brake hose mounting bolt (D).
  1. Remove the pads (A) and piston shim (B).
  1. Remove the pad retainers (A).
  1. Clean the caliper bracket (B) thoroughly; remove any rust, and check for grooves and cracks.
  1. Check the brake disc for damage and cracks.
  1. Apply a thin coat of Molykote M77 grease to the caliper bracket on their mating surfaces (indicated by the arrows) against the retainers.
  1. Install the pad retainers. Wipe excess grease paste off the retainers. Keep any grease paste off the disc and pads.
  1. Mount the brake caliper commercially available piston compressor (A) on the caliper body (B).
  1. Press in the piston with the brake caliper piston compressor so the caliper will fit over the brake pads. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down.
    NOTE: Be careful when pressing in the piston; brake fluid might overflow from the master cylinder's reservoir.
  1. Remove the brake caliper piston compressor.
  1. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.
  1. Peel off pattern paper from the sticky shim (A), and stick and press it to the shim surface of the inner pad and the outer pad.
    The sticky shim is made of stretch material and is not detachable. Make sure to stick it carefully.
    NOTE:
    • Make sure that no grease content on the shim surface.
    • Align the form of the sticky shim to the shim as shown.
  1. Clean and degrease the outer supporting part (A) and the contact side of the piston (B) and the shim (C) of the front caliper. Make sure that no grease content was left.
  1. Peel the backing paper of the sticky shim that was attached to the inner pad and the outer pad.
  1. Apply a thin coat of Molykote M77 grease to the areas indicated by arrows. Wipe excess grease off the pads. Contaminated brake disc or pads reduce stopping ability. Keep grease off the brake disc and pads.
  1. Install the piston shim, then install the brake pads correctly.
    If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency.
    NOTE:
    • Do not hold the sticky shim when installing the brake pad.
    • Keep any contaminant off the sticky shim.
    • Return the piston fully so as to prevent damaging the sticky shim.
  1. Pivot the caliper (A) down into position. Install the new flange bolt (B), and tighten it to the specified torque while holding the caliper pin (C) with a wrench. Be careful not to damage the piston boot and the pin boot.
  1. Install the brake hose mounting bolt, and tighten it to the specified torque.
  1. Start the engine, press the brake pedal for 10 seconds (pedal pressure: 20 kgf).
    NOTE: This is to settle the sticky shim.
  1. Press the brake pedal several times to make sure the brakes work.
    NOTE: Engagement 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.
  1. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.
    Test-drive the vehicle, then check for leaks.