All brakes
1. Check up liquid level in a tank of the main brake cylinder.
2. If the brake fluid level is in the middle between the maximum and minimum level marks, then it is not necessary to remove the fluid from the reservoir before starting to replace the pads.
3. If the brake fluid level is above the middle, pump out the fluid to the middle between the marks.
4. Raise the vehicle and place the safety struts under the frame.
5. Remove the front (or rear) wheel.
6. To facilitate the removal and correct subsequent installation of the pads, insert the brake caliper pistons into the caliper:
- install a large clamp on the caliper body and on the outer brake shoe;
- slowly move the jaws of the clamp until the pistons are fully inserted into the caliper;
- remove the clamp.
1500 series front brake and 2500 series rear brake
7. If possible, completely clean the surface of the caliper from dirt.
Attention: to prevent the loss of brake fluid and the ingress of dirt into the system, plug open openings.
8. Turn away a bolt of fastening of a brake hose to a support.
Series 1500
Tightening torque 40 Nm.
Series 2500, front brake
Tightening torque 45 Nm.
Series 2500, rear brake
Tightening torque 45 Nm.
9. Remove and discard the two brass brake hose banjo seals.
10. Remove the brake hose from the caliper.
Attention:
- On 1500 Series models, use hand tools only when loosening and tightening the guide pin bolts.
- On 1500 Series models, hold the guide pin with an open end wrench when loosening and tightening the guide pin bolts. Do not allow the key to contact the caliper.
Series 1500
11. Turn away bolts of directing fingers of a brake support.
Series 1500
Tightening torque 100 Nm.
Series 2500
Tightening torque 108 Nm.
12. Remove the caliper from the support bracket.
13. Installation is carried out in the reverse order.
Rear brake, 1500 series
7. If possible, completely clean the surface of the caliper from dirt.
Attention: to prevent the loss of brake fluid and the ingress of dirt into the system, plug open openings.
8. Turn away a bolt of fastening of a brake hose to a support.
Tightening torque 45 Nm.
9. Remove and discard the two brass brake hose banjo seals.
10. Remove the brake hose from the caliper.
Attention:
- When loosening and tightening the guide pin bolts, use only hand tools.
- When loosening and tightening the guide pin bolts, hold the guide pin with an open end wrench. Do not allow the key to contact the caliper.
11. Turn away bolts of directing fingers of a brake support.
Tightening torque 38 Nm.
12. Remove the brake caliper from the support bracket.
13. Installation is carried out in the reverse order. Before installing the guide pin bolts, apply locking adhesive to the bolt threads.
All brakes
14. Bleed the brake system.