Removal and installation of a brake disk

Removing

1. Loosen the wheel bolts, then lift the appropriate part of the vehicle and secure it on stands.

2. Remove the corresponding wheel.

Front caliper FN-3



3. Unscrew the two bolts securing the caliper to the steering knuckle and, using a soft wire, hang the caliper to the body.

Front caliper FS-III

4. Remove the front brake pads.

Rear wheel support

5. Remove the two bolts securing the caliper holder to the rear beam.

6. Using hooked wire, secure the caliper to the car body.

7. The brake caliper must not hang on the brake hose. The brake hose must not be stretched or kinked.

8. Unscrew the brake disc fixing screw.

9. Remove the brake disc.

Installation

1. Check the condition and measure the brake disc thickness.

Warning: If the brake disc needs to be replaced, the second brake disc must also be replaced to ensure uniform braking. When replacing the brake discs, the brake pads must also be replaced.

2. Check and, if necessary, clean the mating surfaces of the brake disc and hub.

3. When installing a new brake disc, remove the protective coating from its surface.


4. Install the brake disc on the hub and secure it with the screw.

Front caliper FS-III

5. Install the front brake pads.

Front caliper FN-3

6. Install the caliper along with the brake pads.

7. Fix the caliper with bolts, tightening them with a torque of 125 Nm.

Rear wheel support

8. Install the caliper and secure it with bolts, tightening them to a torque of 65 Nm. Connect the handbrake cable.

9. Install the wheel, then lower the vehicle and tighten the wheel bolts to 120 Nm.

11. Press the brake pedal hard several times to press the brake pads against the brake disc.

12. Check the brake fluid level in the reservoir and top up if necessary.

13. Adjust the handbrake cable.

Security Control Check

1. Check if the brake hoses are securely tightened.

2. Check if the brake hose is fixed in the holder.

3. Check if the bleeder fittings are securely tightened.

4. Check if the brake fluid level is sufficient.

5. Check with the engine running. Within about 10 seconds, press the brake pedal with a force of 20–30 kg / m, while the pedal should not fall through.

6. Check the tightness of all listed connections.