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 (Except KQ Model)

1. Raise the front of the vehicle, and support it with safety stands in the proper locations.

1. Remove the front wheels.

1. Check the thickness of the inner pad (A) and outer pad (B). Do not include the thickness of the backing plate.

   Brake pad thickness:
   | Standard: | 10.5−11.5 mm (0.41−0.45 in.)
   | Service limit: | 1.6 mm (0.06 in.)

1. If the brake pad thickness is less than the service limit, replace all the pads as a set.

Inner pad
Outer pad

Replacement (Except KQ Model)

1. Raise the front of the vehicle, and support it with safety stands in the proper locations.

1. Remove the front wheels.

1. Remove the housing clip (A).

1. Remove the brake hose mounting bolts (A).

1. Remove the caps (B) and pin bolts (C), then remove the caliper (D).

1. Remove the outer pad (A) from the caliper bracket.

1. Check the brake disc for damage and cracks.

1. Remove the inner pad (A) from the caliper body.

1. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.

1. Apply Molykote M77 grease to the areas indicated by the arrows. Wipe excess grease off the pads (A). Contaminated brake discs or pads reduce stopping ability. Keep grease off the brake discs and pads.

1. Push in the piston (B) so that the caliper will fit over the pads.

1. Install the inner pad to the caliper body, and install the outer pad to the caliper bracket (C). If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency.

1. Install the caliper (D) into position. Install the pin bolts, and torque it to the specified torque being careful not to damage the guide.

1. Install the brake hose mounting bolt, and tighten it to the specified torque.

Inner pad
Outer pad

1. Install the housing clip (A).

1. Press the brake pedal several times to make sure the brakes work, then test-drive the vehicle.
   NOTE: Engagement of the brake 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.

1. Install the front wheels.

Inspection (KQ Model)

1. Raise the front of the vehicle, and support it with safety stands in the proper locations.

1. Remove the front wheels.

1. Remove the brake pads.

1. Check the thickness of the brake pads (A). Do not include the thickness of the brake pad backing plate (B).

   Brake pad thickness:
   | Standard: | 10.5−11.5 mm (0.41−0.45 in.)
   | Service limit: | 1.6 mm (0.06 in.)

1. If the brake pad thickness is less than the service limit, replace all the pads as a set.

Replacement (KQ Model)

1. Raise the front of the vehicle, and support it with safety stands in the proper locations.

1. Remove the front wheels.

1. Remove the brake hose mounting bolts (A).

1. Remove the flange bolt (B) while holding the pin (C) with a wrench being careful not to damage the pin boot, and pivot the caliper (D) up out of the way. Check the hose and pin boots for damage and deterioration.

1. Remove the pad shims (A) and pads (B).

1. Remove the pad retainers (A).

1. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.

1. Check the brake disc for damage and cracks.

1. Clean and install the pad retainers.

1. Apply Molykote M77 grease to the pad side of pad shim A, B, both sides of outer pad shim (C), the back of pads (D), and to the other areas indicated by the arrows. Wipe excess grease off the shims and pads. Contaminated brake discs or pads reduce stopping ability. Keep grease off the brake discs and pads.

1. Install the brake pads and pad shims correctly. Install the pad with the wear indicator (E) on the inside.
   If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency.

1. Push in the piston (A) so that the caliper will fit over the pads. Make sure the pin boot is in position to prevent damaging it when pivoting the caliper down.

1. Pivot the caliper (B) down into position. Install the flange bolt (C), and torque it to the specified torque while holding the pin (D) with a wrench being careful not to damage the pin boot.

1. Install the brake hose mounting bolt, and tighten it to the specified torque.

1. Press the brake pedal several times to make sure the brakes work, then test-drive the vehicle.
   NOTE: Engagement of the brake 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.

1. Install the front wheels.