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BRAKES 5C-31
ADJUSTMENT PROCEDURE OF BRAKE PEDAL
The push rod serves as the brake pedal stopper when the
pedal is fully released.
Brake pedal height adjustment should be performed as follows.
RTW35CSH000601
Brake Pedal - Height
Measure the brake pedal height after making sure the pedal is
fully returned by the pedal return spring.
Note:
Pedal height (L2) must be measured after starting the
engine and increasing the revolution several times by
stepping on the accelerator pedal.
mm(in)
Pedal free play (L1) 6-10 (0.23 - 0.39)
M/T 174-186 (6.85-7.32)
RHD
LHD
A/T 176-188 (6.93-7.40) Height (L2)
Note:
Pedal free play must be measured after turning off the
engine and stepping on the brake pedal firmly five times
or more.
If the measured value deviates from the above range, adjust
the brake pedal as follows:
a) Disconnect the stop lamp switch.
b) Loosen the lock nut on the push rod.
c)
Adjust the brake pedal to the specified height by rotating the
push rod in the appropriate direction.
Lock Nut Torque N
m(kgf
m/lb
ft)
12 - 18 (1.2 – 1.8 / 9 - 13)
d) Install the stop lamp switch.
Note:
Pedal height (L
2) must be 80 mm (3.14 in.) or more when
applying about 50 kg (110.25 lbs.) of stepping force.
331R300005
How to connect the CLEVICE of BOOSTER ROD with PEDAL
ARM. and how to adjust the PEDAL SW.
After connecting the CLEVIS of BOOSTER ROD with PEDAL
ARM, adjust the PEDAL SW mounted (PDA) to PEDAL
BRACKET by the procedure explained still more bellow.
1. Set the hole of the CLEVIS of BOOSTER&M/CYL ROD
with the hole of the PEDAL ARM.
2. Enter the PIN; PUSH ROD to PEDAL to these holes
from left side of the PEDAL.
3. Enter and fix the PIN; SANP PIN FIX to the DITCH o
f
the PIN; PUSH ROD to PEDAL from right side of the
PEDAL.
4. Release the LOCK by turning the SWITCH counter-
clock-wise.
Page 458 of 4264
5C-32 BRAKES
5. After doing so, pull PEDAL ARM to yourself a little so
that PEDAL ARM is not pushed in.
6. Making PEDAL ARM not movable with one hand, push
in the whole SWITCH with the other hand until the
PLUNGER of SWTCH is pushed in and SWITCH itself
hits the RUBBER of PEDAL ARM.
In the condition, turn SWITCH clock-wise until “click”
sound is made and lock it.
By doing this the SWITCH is adjusted at 0.70.5mm
clearance.
Page 459 of 4264
BRAKES 5C-33
FRONT BRAKE ASSEMBLY
REMOVAL AND INSTALLATION
Removal Steps
1. Brake flexible hose
2. Lock bolt
3. Pad assembly
4. Clip; pad
5. Caliper assembly
6. Support bracket
7. Front hub and disc assembly
Installation Steps
7. Front hub and disc assembly
6. Support bracket
5. Caliper assembly
4. Clip; pad
3. Pad assembly with shim
2. Lock bolt
1. Brake flexible hose
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5C-34 BRAKES
Important Operations - Removal
1. Brake Flexible hose
Remove the bolt and gasket and disconnect the brake flexible
hose from the caliper.
After disconnecting the flexible hose, cap or tape the openings
to prevent entry of foreign material.
2. Lock Bolt
Remove the lock bolt from the caliper.
3. Pad Assembly with Shim
Rotate the caliper upward.
Mark the lining locations if they are to be reinstalled.
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BRAKES 5C-35
6. Support Bracket
Take care not to damage the flexible brake hose when
removing the support bracket.
7. Front Hub and Disc Assembly
For the removal procedure, refer to Section 4C "FRONT
WHEEL DRIVE".
Important Operations - Installation
7. Front Hub and Disc Assembly
For the installation procedure, refer to the front hub and disc
reassembly procedure in Section 4C "FRONT WHEEL
DRIVE".
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5C-36 BRAKES
6. Support Bracket
Torque Nm(kgfm/lbft)
196 - 235 (20.0 – 24.0 / 145 - 174)
Set up the clip and pad before installation of the support
racket.
4. Clip ; Pad
Install new parts if necessary.
2. Lock Bolt
Torque N
m(kgf
m/lb
ft)
32 - 40 (3.3 – 4.1 / 24 - 30)
1. Brake Flexible Hose
Attach the bolt and new gasket
Torque Nm(kgfm/lbft)
29 -39 (3.0 - 4.0 / 22 - 29)
After installation, bleeding and replenishing procedure must be
performed.
Wipe the circumference of the hose clean.
Note:
Always use new gaskets.
Be sure to put the hooked edge of the flexible hose end into
the anti-rotation cavity.
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BRAKES 5C-37
REMOVAL AND INSTALLATION OF DISC PAD
Removal Steps
1. Lock Bolt
Remove the lock bolt from the caliper.
Note:
Don't remove the brake hose from caliper when replacing
pads.
2. Rotate the Caliper Upward
Remove the caliper from the support bracket and the caliper to
the upper link or the frame.
Note:
While caliper is removed from support bracket, never step
on the brake pedal or the piston will protrude rapidly.
3. Pad Assembly with Shim
Remove the pad assembly with the shim.
Mark the pad locations if they are to be reinstalled.
4. Clip ; Pad
Discard the used clip and install a new one.
Installation Steps
1. Clip ; Pad
2. Pad Assembly with Shim
After attaching the pad assembly with the shim to the support
bracket, position the wear indicator to the lower side of the
inner pad and position the wear indicator to the upper side of
the outer pad.
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5C-38 BRAKES
3. Caliper Assembly
Lower the caliper into its original position.
Do not damage the flexible hose by twisting or pulling it.
4. Lock Bolt
Attach the lock bolt to the caliper.
Torque Nm(kgfm/lbft)
32 - 40 (3.3 – 4.1 / 24 - 30)