Attention: replacement of pads must be carried out simultaneously on both wheels of the same axle. Cleaning of brake parts is carried out only with denatured alcohol.
Note: When servicing brakes, use only high quality parts with recognizable markings.
1. Remove the brake fluid reservoir cap.
2. Loosen the wheel nuts, raise the vehicle and place it on stands.
3. Remove the wheel. We do not recommend working with several wheels at the same time. Replace pads one by one.
4. Carefully inspect the brake disc (see Section 4) - if its repair is required, it must be carried out before replacing the pads.
Front pads
5. Push the piston into the cylinder to provide sufficient clearance for the new pad. To facilitate this procedure, you can use a clamp. As the piston enters the brake caliper cylinder, the fluid level in the reservoir rises. Make sure that there is no overflow: if necessary, remove excess brake fluid.
Pic. 2.5 Release the brake cylinder
6. For the next steps to replace the pads, see fig. 2.6a-2.6b. After completing work on this item, go to step 8. Rear pads.
Pic. 2.6a Tokico front brake assembly: 1 - bleed valve; 2 - pad retainer; 3 - support; 4 - pads; 5 - guide pin; 6 - guide bolt; 7 - guide pads; 8 - anther; 9 - guide pin; 10 - pad pusher; 11 - anther; 12 - piston; 13 - piston seal; 14 - caliper bolt.
Pic. 2.6b Sumitomo front brake assembly: 1 - bleed valve; 2 - caliper bolt; 3 - pad retainer; 4 - plate of clamps; 5 - pads; 6 - guide bolt; 7 - guide pads; 8 - guide bushing; 9 - anther; 10 - piston; 11 - pad pusher; 12 - piston seal; 13 - support.
Pic. 2.6c Nissin front brake assembly: 1 - guide bolt; 2 - anther; 3 - guide; 4 - pad retainer; 5 - pad pusher; 6 - latch; 7 - block; 8 - support; 9 - piston; 10 - anther ring; 11 - anther; 12 - seal; 13 - guide bolt; 14 - banjo bolt; 15 - sealing washers; 16 - bleed valve; 17 - caliper bolt; 18 - holder; 19, 20 - guide bushings.
Pic. 2.6g Remove the caliper mounting bolt
Pic. 2.6d Turn the caliper up
Pic. 2.6e Remove the pad pusher
Pic. 2.6g Remove outer shoe
Pic. 2.6i Remove the brake pads (bottom bracket shown): pay special attention to the position of the detent springs
7. Following the instructions of Figures 2.7c-2.7e, replace the rear brake pads.
Pic. 2.7a Remove the protection bolts (arrows) and caliper protection
Pic. 2.7b Remove the caliper mounting bolts...
Pic. 2.7v... and remove the caliper from the bracket. hang caliper (not for brake hose 1)
Pic. 2.7g Remove pusher and outer shoe
Pic. 2.7e Remove the pusher and the inner shoe
Pic. 2.7f Remove the brake pads (bottom shown)
Front and rear pads
8. Apply an anti-noise compound to the new pads according to the manufacturer's instructions.
9. Establish blocks on pushers.
10. Install the clips on the rail. Lubricate them with a thin layer of silicone grease.
11. Install the pads in the guide.
12. If replacing the front pads, install the caliper mounting bolts and tighten them to specification and proceed to step 15. If replacing the rear pads, go to step 13.
Rear pads
13. Use a pair of pliers to turn the piston clockwise and push it in. then rotate the piston until its grooves align with the tabs on the inner pad installed in the caliper.
Pic. 2.13 Piston adjustment when changing shoes
If the piston boot is bent during adjustment, turn the piston in the opposite direction until the boot is reshaped.
14. Install the caliper guard.
Front and rear pads
15. Install the wheel and mounting nuts, lower the vehicle and tighten the nuts.
16. Check the brake fluid level. Top up if necessary (see chapter 1).
17. Press the brake pedal several times to install the pads in their place. Check the operation of the brakes in a closed area from traffic.