Check intervals for rubber components and brake booster A. Checking the operation of the brake booster Depress the brake pedal and check the braking efficiency. If the efficiency is insufficient, check the operation of the brake booster and its tightness (see below). If the...
Checking and adjusting the brake pedal Pedal Height Measure the distance from the pedal to the floor surface. Unscrew the cutout in the insulator and measure the distance from the center of the left edge of the pedal to the metal surface of the floor. After...
Checking and adjusting the parking brake pedal Examination Depress the parking brake pedal with a force of 294 N (30 kg) and check pedal travel (count the number of clicks). Pedal travel: 5-7 clicks (when pressing the pedal with a force of 294 N (30 kg)) If the...
Brake system — pumping Attention: Keep foreign particles and water out of the system when adding brake fluid. To prevent chemical changes in the brake fluid, do not mix fluids of different types. Use genuine Honda Ultra DOT 3 or DOT 4 brake...
Front brake pads — check and replace Examination Check pad thickness. If the pad thickness is less than the limit, replace the inner and outer pads as a set. Standard shoe thickness: 11mm Maximum pad thickness: 1.6 mm Without taking into account the...
Front brake discs — check for runout When replacing a brake disc with a new one, check it for runout. 1. Fix the brake disc securely with the wheel nuts. Use suitable flat washers to prevent damage to the conical sections of the wheel nuts. 2. Place the...
Front Brake Discs — Thickness and Parallelism Check 1. Check for cracks, excessive nicks and stepped wear due to wear on the friction surfaces of the disc. 2. Measure the disc thickness at a distance of 10 mm from its edge at 8 points in approx. 45°. The minimum...
Front brake discs — grinding the brake disc 1. Grind with a brake disc grinder. For grinding, see the instructions for the grinding machine. Grind the disc so that the thickness of the disc remains greater than the limit. Limit thickness: 2WD Models: 21.0mm 4WD...
Front brake caliper — disassembly Attention. Be careful not to get brake fluid on paintwork. If the liquid does get on the paintwork, immediately wash it off with water. Install plugs on disconnected hoses to prevent spillage of brake fluid. Flush the...
Front brake caliper assembly Attention: Do not apply oil to the friction surfaces of the disc and pads. Be sure to replace non-reusable components with new ones. Do not allow foreign particles to enter the cylinders and anthers. Be careful not to...
Master cylinder and brake booster — removal and installation Attention: Be careful not to get brake fluid on paintwork. If the liquid does get on the paintwork, immediately wash it off with water. Do not damage or severely deform the brake pipes during removal and installation....
Master cylinder disassembly Attention: Replace unused components. Flush the removed components with brake fluid and blow out all ports with compressed air. Keep foreign matter away from removed components. 1. Remove the master cylinder. 2. Remove...
Master cylinder assembly Attention: If the primary, secondary pistons or master cylinder body have been changed, be sure to check and adjust the gap in the pressure rod (see below). Be sure to replace unused components. Do not reuse drained...
Checking and adjusting the push rod clearance This check is performed when the master cylinder body, primary/secondary piston or brake booster is replaced. Gap measurement is performed using a special tool as follows. 1. Place the special tool firmly on the master...
Checking the functioning of the brake booster 1. Start the engine and warm it up until the fan turns on twice. 2. Stop the engine. 3. Depress the brake pedal with force, as during normal braking. 4. If the pedal travel is large during the initial pressing, and the...
Adjustment of the length of the pressure rod with an earring This adjustment must be carried out if the brake booster is replaced or after removing the shackle. Before adjusting the length, check the clearance in the push rod and adjust if necessary (see above). 1. Measure the...
Rear brake pads — check and replace Examination Measure the thickness of the pads and if it is less than the limit, replace the pads as a set. Standard Thickness: 9.0mm Limit Thickness: 1.6mm The thickness of the metal plate is not taken into account....
Rear brake discs — check for runout 1. Fix the brake disc securely with wheel nuts. Use flat washers to prevent damage to the taper portions of the nuts. 2. Install the indicator at a distance of approx. 10 mm from the edge of the disc, as shown in the...
Rear Brake Discs — Thickness and Parallelism Check 1. Check the friction surfaces of the disc for cracks and stepped wear. 2. Measure the disc thickness at 8 points 10 mm from the outer edge in approx. 45°. The minimum value among the measured values is compared to....
Rear brake discs — grinding the brake disc 1. Grind with a grinder (available for sale). Attention. Carry out grinding with an electric machine. For the use of the grinder, see the instruction manual for the machine. Grind so that the thickness of the disc does...
Rear brake caliper — disassembly Attention: Be careful not to get brake fluid on paintwork. If the liquid does get on the paintwork, immediately wash it off with water. To prevent leakage of brake fluid, install plugs on the disconnected pipes. Be...
Rear brake caliper — assembly Attention. Be sure to replace non-reusable components with new ones. Do not allow foreign particles to enter the cylinders, anthers and rubbing surfaces of the fingers. Be careful not to get brake fluid on paint...
Parking brake — check Attention. Do not apply grease or oil to the friction surfaces of the friction linings and the brake drum. The illustration shows the left parking brake. Attention. Do not apply grease or oil to the friction surfaces of...
Removing the parking brake pads Attention. If new pads are installed, adjust the parking brake lever travel and then break in the friction linings. 1. Remove the rear brake caliper and remove the brake drum/disc ( see ch. Front and rear suspension )....
Installing the parking brake pads 1. Apply Morikoto 44MA grease to the operating arm axle and install on a new pad. Install the operating arm and wave washer on the axle and secure them with a new U-clamp. Apply lubricant to Morikoto 44MA on friction...
Run-in of friction linings of the parking brake After replacing the brake pads or the brake drum, the friction linings must be run in. Attention. This procedure requires travel. Run in in a safe area. 1. Make sure the parking brake pedal is properly adjusted before...
Brake hoses and tubes — check 1. Check the brake hoses for damage, contact with other components and for leaks. 2. Check the brake pipes for pinching, bending, damage, rust, and fluid leaks. 3. Check for kinked hoses at tubing connections and for...
Brake hoses and tubes — replacing hoses Keep foreign particles away from all components. Do not install components that are not reused. Be careful not to get brake fluid on paintwork. If the liquid does get on the paintwork, immediately wash it off with...
Parking brake cable — replacement Attention. When removing and installing the cable, do not twist or bend the cable excessively. A deformed cable may cause the parking brake to not work satisfactorily or cause the cable to break. 1. Loosen the wheel...
ABS System Fault Diagnosis — Preliminary Remarks ABS warning lamp 1. If the system is OK, the ABS warning lamp goes out after approx. 2 seconds after turning the ignition key to the ON position (II). During this time, a system check is performed. If the engine is then...
ABS Diagnostic Trouble Codes (DTCs) 1. If a malfunction occurs in the system, the control unit (CPU) determines the location and nature of the malfunction and writes the DTC code to non-volatile memory. 2. DTCs are cleared only when certain procedures are...
Modulator assembly — removal and installation Withdrawal 1. Pull up on the ABS control unit 25-track connector and disconnect the connector. 2. Disconnect 6 brake pipes. 3. Remove 2 nuts (6 mm). 4. Remove the modulator assembly. Attention. Be careful not to get...
Wheel sensors — check 1. Check for chips on signal discs. Replace if necessary. 2. Check the gap between the wheel sensor and signal disc. Standard Clearance: Front sensors: 0.4-1.0mm If the clearance is not as specified, check the wheel...