Inspection and replacement
There are 6 types of front brake mechanisms, which can be classified into 3 groups (type A, type B and type C). Check the type of brake mechanism before starting work because the operation procedure differs depending on the type of mechanism.
A type: Nissin mechanism
Type: Akebono mechanism (for 14" and 15" wheel rims)
C type: Akebono mechanism (for 13" wheel rims)
Note:
- A Nissin movement and an Akebono movement can be identified by the Nissin mark on the body of the Nissin movement.
- Front brake disc OD for 14" and 15" wheel rims: 262 mm
- Front brake disc OD for 13" wheel rim: 240 mm
Type A and type B:
Note: For operating procedures for type C, see below.
Warning
- Never use an air hose or dry brush to clean brake components.
- Use a vacuum cleaner to prevent brake dust from entering your respiratory tract.
1. Slightly loosen the front wheel nuts, then jack up the machine and secure it on safe stands.
2. Remove the brake hose fasteners from the steering knuckle.
3. Remove the mechanism bolt and turn the mechanism over.
Note: Check the hoses and axle boots for damage or destruction.
4. Remove the pad plates, pad holders and pads.
Note: When the brake mechanism is equipped with an outer plate, replace the plate and pad as a unit.
5. Using calipers, measure the thickness of each brake pad.
Brake lining thickness:
Standard
For 13" wheel rim: 8.5-9.5 mm
For 14" and 15" wheel rims: 9.5-10.5 mm
Operational values: 1.6 mm
Note: Measurements do not include the thickness of the pad mounting plate.
6. If the thickness of the brake lining is less than the operating values, replace the entire front pads.
7. Clean the mechanism thoroughly, remove rust and check for grooves and cracks.
8. Check the brake disc for damage and cracks.
9. Install the pad holders.
10. Apply lubricant to the points indicated by arrows in the illustration.
Note: use the pad lubricant included in the kit or M77 lubricant (Molikot) and apply a thin layer of lubricant even to the indicated points.
- Piston and contact surface of the inner pad
- Block and contact surface of the mechanism support
- External lining and contact surface of the mechanism body. Mechanism with external block control plate
- Control plate of the block and contact surface of the outer block Control plate of the block and contact surface of the mechanism body
11. Install the brake pads and pad plates correctly.
Warning
- When reusing the pads, always return them to their original position to prevent loss of brake performance.
- Dirty brake discs or pads reduce braking performance. Remove grease from discs and pads.
Note: Install the wear indicator pad on the inner side.
12. Push the piston so that the mechanism sits on top of the pads. Make sure the piston boot is in a position that will not damage it when turning over.
13. Turn the mechanism down into place, then install the bolt and tighten it.
Warning: Be careful not to damage the axle boot when turning the mechanism down.
14. Install the brake hose fasteners onto the steering knuckle.
Note: Inspect the brake hose for snagging and kinking.
15. Press the brake pedal several times to make sure the brakes work, then test the car in motion.
Note: Engaging the brakes may require more pedal travel immediately after replacing the pads. A few presses on the brake pedal will restore normal pedal travel.
16. After installation, check hoses and line connections or connectors for leaks and tighten if necessary.
Type C:
Warning
- Never use an air hose or dry brush to clean brake components.
- Use a vacuum cleaner to prevent dust from entering your respiratory tract.
1.Slightly loosen the front wheel nut, then lift the machine and secure it on safe stands.
2.Remove the brake hose fastening from the steering knuckle.
3.Remove bolt B of the mechanism and turn the mechanism upside down.
Note: Check the hoses and axle boots for damage or destruction.
4. Remove the pad plate, pad holders and pads,
Note: When replacing a pad, replace the plate with the pad as a set.
5. Using a caliper, measure the lining thickness of each brake pad.
Brake lining thickness:
- Standard: 8.5-9.5 mm
- Operational values: 1.6 mm
Note: Measurements do not include the thickness of the pad mounting plate.
6. If the thickness of the brake lining is less than the service value, replace the front pads as a set.
7. Clean the mechanism thoroughly, remove rust and check for grooves and cracks.
8. Check the brake disc for damage and cracks.
9. Install the pad holders.
10. Apply lubricant to the points indicated by arrows in the illustration.
Note: use the pad lubricant included in the kit or M77 lubricant (Malikot) and apply a thin layer of lubricant even to the designated points.
- Piston and contact surface of the inner pad
- Block and contact surface of the mechanism bracket
- External block and contact surface of the mechanism body
- Outer pad plate and outer pad contact surface
- External block plate and contact surface of the mechanism body
11. Install the brake pads and pad plate correctly.
Warning
- When reusing the pads, always return them to their original position to prevent loss of brake performance.
- Dirty brake discs or pads will reduce the effectiveness of the brakes. Remove grease from discs and pads.
Note: Install the wear indicator pad on the inner side.
12. Push the piston so that the mechanism sits on top of the pads. Make sure that the piston boot is in a position that will not damage it when turning the mechanism down.
13. Turn the mechanism down into place, then install bolt B and tighten it.
14. Install the brake hose mount on the steering knuckle.
Note: Inspect the brake hose for pinches or kinks.
15. Press the brake pedal several times to make sure the brakes work, then test the car in motion.
Note: Engaging the brakes may require more pedal travel immediately after replacing the pads. A few presses on the brake pedal will restore normal pedal travel.
16. After installation, check hoses and line connections or connectors for leaks and tighten if necessary.