The first step to service the front brake caliper involves disconnecting the flexible hose by removing its union bolt together with 2 gaskets. Verify that brake fluid drains into a container before torquing the union bolt to 30 Nm (310 kgf-cm, 22 ft. lbs.). During reinstallation, use 2 new gaskets and secure the flexible hose lock into the caliper lock hole. After holding the sliding pin begin unfastening the two installation bolts until the caliper is free from the torque plate. After removing the
Brake Pads, their attached anti-squeal shims together with the 4 pad support plates should be discarded. To disassemble the unit begin by removing the cylinder boot set ring and cylinder boot with a screwdriver before inserting a cloth between piston and caliper for compressed air removal of the piston which requires avoiding finger placement in front of the piston. Apply a screwdriver to extract the piston seal and proceed to remove the two sliding pins along with their two dust boots. Regular inspection requires pad lining thickness measurement with a ruler at 12.0 mm (0.472 in.) standar d thickness while keeping 1.0 mm (0.039 in.) as the minimum; pad replacement is needed when meeting or falling under minimum thickness or showing severe uneven pad wear. A micrometer should measure disc thickness which must have a standard size of 25.0 mm (0.984 in.) and a minimum threshold of 23.0 mm (0.906 in.). Consequences of meeting or falling below the minimum threshold or revealing scoring or uneven wear require disc replacement or possible grinding. To measure disc runout use a dial indicator 10 mm (0.39 in.) from the edge while 0.05 mm (0.0020 in.) runout stands as the maximum tolerance; inspect bearing play and axle hub runout before performing necessary adjustment or grinding to the disc. Every adjustment requires removal of both knuckle bolts along with the torque plate followed by disc hub nuts until the disc obtains a 1/5 rotation beyond its original orientation before torquing the hub nuts to 103 Nm (1,050 kgf-cm, 76 ft. lbs.). Follow this procedure again to achieve minimum runout levels under 0.05 mm (0.0020 in.) then torque the mounting bolts to 106 Nm (1,090 kgf-cm, 78 ft. lbs.) while using the torque plate. The process of reassembly must be conducted in reverse order of disassembling steps while applying lithium soap base glycol grease to designated parts before their installation in the correct sequence of removal steps; post installation involves fluid addition into the brake reservoir followed by system bleeding then leak inspection.