Front

FRONT DISC BRAKE ASSEMBLY

DISASSEMBLY AND ASSEMBLY [15-INCH FRONT DISC BRAKE]

Disassembly Steps 1-14:

NOTE:
^ The brake pad assembly with wear indicator is installed only to the inner side of the brake disc of the left-side brake at factory.
^ As for the accessory pad set, the brake pad with wear indicator has been established to the inner side of the brake disc on both right and left.
^ Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the top.

DISASSEMBLY SERVICE POINTS

[[A]] PISTON BOOT/PISTON REMOVAL

CAUTION
Blow air gradually to remove the pistons. The pistons will rush out if a force of air is applied suddenly.





Cover the caliper body outer side with a cloth or similar materials.

Blow compressed air through the brake hose installation area to remove the piston and piston boot.

[[B]] PISTON SEAL REMOVAL

CAUTION
Do not use a flat-tipped screwdriver to remove the piston seal. This may damage the inner side of the cylinder.





1. Remove the piston seal with your finger tip.
2. Clean the piston surface and cylinder inner face with alcohol or specified brake fluid.

Brake fluid: DOT3 or DOT4

DISASSEMBLY AND ASSEMBLY [16-INCH FRONT DISC BRAKE (EXCEPT RALLIART)]

Disassembly Steps 1-14:

DISASSEMBLY SERVICE POINTS

[[A]] PISTON BOOT/PISTON REMOVAL

CAUTION
Blow air gradually to remove the pistons. The pistons will rush out if a force of air is applied suddenly.





Cover the caliper body outer side with a cloth or similar materials. Blow compressed air through the brake hose installation area to remove the piston and piston boot.

[[B]] PISTON SEAL REMOVAL

CAUTION
Do not use a flat-tipped screwdriver to remove the piston seal. This may damage the inner side of the cylinder.





1. Remove the piston seal with your finger tip.
2. Clean the piston surface and cylinder inner face with alcohol or specified brake fluid.

Brake fluid: DOT3 or DOT4

DISASSEMBLY AND ASSEMBLY [16-INCH FRONT DISC BRAKE (RALLIART)]

Disassembly Steps 1-15:

NOTE:
^ The brake pad assembly with wear indicator is installed only to the inner side of the brake disc of the left-side brake at factory.
^ As for the accessory pad set, the brake pad with wear indicator has been established to the inner side of the brake disc on both right side brake and left side brake.
^ Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the top.

DISASSEMBLY SERVICE POINT

[[A]] PISTON BOOT/PISTON REMOVAL

CAUTION
^ Blow air little by little to remove the pistons. The pistons will rush out if a force of air is applied suddenly.
^ If one piston has been removed completely, it will become impossible to remove the second piston.





Remove the pistons and the piston boots by pumping in air from the brake hose connection. Be sure to use the handle of a plastic hammer and adjust the height of the two pistons so that the pistons protrude evenly.

[[B]] PISTON SEAL REMOVAL

CAUTION
Do not use a flat-tipped screwdriver or similar tool to remove the piston seal. These may damage the inner side of the cylinder.





1. Remove the piston seal with your finger tip.
2. Clean the piston surface and cylinder inner face with alcohol or specified brake fluid.

Brake fluid: DOT3 or DOT4

INSPECTION

BRAKE PAD WEAR INSPECTION

CAUTION
^ When replacing, replace both brake pad assembly (right and left) as a set.
^ If there is a significant difference in thickness between the brake pads at right and left, check the sliding area of the brake caliper.





Measure the brake pad thickness at the most worn area. If the brake pad thickness is less than the limit value, replace the brake pad.

Standard value: 10.0 mm (0.39 inch)
Limit: 2.0 mm (0.08 inch)