Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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WARNING: 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 brush assembly. Use an OSHA-approved vacuum cleaner. REAR DISC BRAKE PADS Removal Raise and support vehicle. Remove wheels. Thoroughly clean outside of caliper to prevent dust and dirt from entering inside. Support caliper with a piece of wire to prevent damage to brake hose. Remove 2 caliper bolts and caliper from bracket. Remove pad shims and pads. Using vernier calipers, measure the thickness of each brake pad lining. Measurement does not include pad backing plate thickness. See DISC BRAKE SPECIFICATIONS . Remove pad retainers. Inspection Clean caliper thoroughly; remove any rust, and check for grooves and cracks. Check brake disc for damage and cracks. Measure brake pad thickness. See DISC BRAKE SPECIFICATIONS . If brake pad thickness is less than service limit, replace pads as a set. Installation 1. Install pad retainers. Apply Molykote M77 compound onto pad side of shim. Wipe excess grease off shim. Keep grease off discs and pads. Install brake pads and shims. Install inner pad with its wear indicator facing downward. If you are reusing pads, install in original position. Rotate caliper piston clockwise into cylinder, then align cutout in piston with tab on inner pad by turning piston back. See Fig. 15 . 2. Lubricate boot with rubber grease to avoid twisting. If boot is twisted, back it out and position properly. Install brake caliper. Install and torque caliper bolts to proper specification. See TORQUE SPECIFICATIONS . Install brake hose onto suspension arm with mounting bolt. After installation, check for leaks. Pump brake pedal several times to seat pads. Bleed brakes as necessary. See BLEEDING BRAKE SYSTEM . NOTE: Engagement of brake may require a greater pedal stroke immediately after brake pads have been replaced as a set. Several applications of brake pedal will restore normal pedal stroke.

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REMOVE TRANSAXLE FROM ENGINE 2. REMOVE CLUTCH COVER AND DISC a. Align the matchmark on the clutch cover with the one on the flywheel. b. Loosen each set bolt one turn at a time until spring tension is released. c. Remove the set bolts, and pull off the clutch cover with the clutch disc. NOTICE: Do not drop the clutch disc. 3. REMOVE RELEASE BEARING AND FORK FROM TRANSAXLE Remove the release bearing with the fork together and then separate them. 4. REMOVE RELEASE FORK SUPPORT AND BOOT INSPECTION 1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE Using vernier calipers, measure the rivet head depth. Minimum rivet depth: 0.3 mm (0.012 inch) If necessary, replace the clutch disc. 2. INSPECT CLUTCH DISC RUNOUT Using a dial indicator, check the disc runout. Maximum runout: 0.8 mm (0.031 inch) If necessary, replace the clutch disc runout. 3. INSPECT FLYWHEEL RUNOUT Using a dial indicator, check the flywheel runout. Maximum runout: 0.1 mm (0.004 inch) If necessary, replace the flywheel. Torque: 1st: 49 Nm ( 00 kgf-cm, 36 ft. lbs.) 2nd: Turn 90° 4. INSPECT DIAPHRAGM SPRING FOR WEAR Using vernier calipers, measure the diaphragm spring for depth and width of wear. Maximum: A (Depth): 0.5 mm (0.020 inch) B (Width): 6.0 mm (0.236 inch) If necessary, replace the clutch cover. 5. INSPECT RELEASE BEARING Turn the bearing by hand while applying force in the axial direction. HINT: The bearing is permanently lubricated and requires no cleaning or lubrication. If necessary, replace the release bearing. INSTALLATION 1. INSTALL CLUTCH DISC AND CLUTCH COVER ON FLYWHEEL

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CAUTION: 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 OSHA-approved vacuum cleaner. 1. Loosen the front wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheels. 2. Remove the brake hose mounting bolt (A) from the knuckle. 3. Hold the caliper pin with a wrench, being careful not to damage the pin boot. Remove the caliper bolt (B) with another wrench. 4. Pivot the caliper (C) up out of the way. Check the hoses and pin boots for damage and deterioration. 5. Remove the pad shims (A), pad retainers (B), and pads (C). The ‘99-01 models have two pairs of pad shims. The ‘02 model has one pair of the pad shims. 6. Using vernier calipers, measure the thickness of each brake pad lining. The measurement does not include pad backing plate (A) thickness. 7. If the brake pad thickness is less than the service limit, replace the front pads as a set. 8. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. 9. Check the brake disc for damage and cracks. Install the pad retainers (A). Apply Molykote M77 grease or Daikalub 528D grease to both sides of the pad shims (A) and the back of the pads (B). Wipe excess grease off the shim. Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads. 12. Install the brake pads and pad shims correctly. The ‘99-01 models have two pairs of the pad shims. The ‘02 model has one pair of the pad shims. Install the pad with the wear indicator (C) on the inside. NOTE: Check the brake fluid level, the brake fluid may overflow the reservoir if too full.

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Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner to avoid breathing brake dust . 1. Loosen the front wheel nuts slightly, then raise the vehicle and support if on safety stands. 2. Remove the caliper bolt, and pivot the caliper up out of the way. NOTE: Check the hoses and pin boots for damage or deterioration. 3. Remove the pad shim, pad retainers and pads. 4. Using vernier calipers, measure the thickness of each brake pad lining. The measurement does not include pad backing plate thickness. Brake Pad Thickness: Standard: Type R Model: 10.5 – 11.5 mm 10.41 – 0.45 inch) All except Type R Model: 9.5 – 10.5 mm (0.37 – 0.41 inch) Service Limit: 1.6 mm 10.06 inch) 5. If the brake pad thickness is less than the service limit, replace the front pads as a set. 6. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.