206-03-1

Front Disc Brake 206-03-1

Section 206-03 Front Disc Brake

Applicable Model: Boomday

CONTENT PAGE
Specifications
Specifications................................................................................................................................. 206-03-2
Descriptions and Operations
Front Disc Brake............................................................................................................................. 206-03-3
Diagnosis and Testing
Front Disc Brake............................................................................................................................. 206-03-4
Removal and Installation
Disc Brake – Parts Illustration........................................................................................................ 206-03-5
Brake Pad....................................................................................................................................... 206-03-6
Brake Caliper.................................................................................................................................. 206-03-7
Brake Caliper Mounting Bracket..................................................................................................... 206-03-8
Brake Disc...................................................................................................................................... 206-03-9
Disassembly and Assembly
Brake Caliper................................................................................................................................ 206-03-10

2009.06 Boomday
206-03-2
Front Disc Brake 206-03-2
Specifications

Material Specifications

Item Specification
D0T 3 Brake fluid SAEJ 1703 or FMVSS 116
Lubricant grease -

Parameters Specifications

Item Specification
Brake pad
Limiting wearout thickness of brake pad 1.0 mm
Max. thickness difference between brake pads 1.0 mm
Brake disc
Diameter of brake disc – Rear wheel drive 257 mm
Diameter of brake disc – All wheel drive 257 mm
Standard thickness of brake disc 22 mm
Min. thickness for brake disc machining
Limiting wearout thickness of brake disc 20.6 mm
Max. radius run-out of brake disc (installation) 0.13 mm

Torque Specifications

Item Nm
Brake caliper guide bolt 33 ± 5
Brake hose bolt 35 ± 5
Brake caliper mounting bracket bolt 158 ± 16
Brake disc mounting bolt 105 ± 10

2009.06 Boomday
 Front Disc Brake
206-03-3 206-03-3
Descriptions and Operations

Front Disc Brake

Brake caliper
● U
 se bolts to connect brake caliper to mounting
bracket which is connected to front steering
knuckle with bolts.
● G
 uide pin sliding, single piston type.

Brake pad
● W
 ithin brake caliper mounting bracket of front
disc brake.
● M
 ounted to support seat of brake caliper
mounting bracket with retaining clip.

2009.06 Boomday
 Front Disc Brake
206-03-4 206-03-4
Diagnosis and Testing

Front Disc Brake

Reference : 206-00 Brake System – General
Information.

2009.06 Boomday
 Front Disc Brake
206-03-5 206-03-5
Removal and Installation

Disc Brake – Parts Illustration

Item Description Item Description

1 Bolt (6) 7 Brake pad
2 Wheel hub 8 Brake caliper guide bolt
3 Brake disc 9 Brake caliper
4 Dust cover bolt (3) 10 Brake pad retaining clip
5 Dust cover 11 Brake caliper mounting bracket
6 Brake caliper mounting bracket bolt (2)

2009.06 Boomday
 Front Disc Brake
206-03-6 206-03-6
Removal and Installation

Brake Pad
Materials 2 Turn up brake caliper.

Item Specification
D0T 3 brake fluid SAEJ 1703 or FMVSS 116

Removal and Installation

 ARNING: The unapproved brake fluids
W
other than D0T 3 will cause brake to work
improperly.Failure to follow the above
Description may result in personal injury.

 AUTION: Do not splash brake fluid onto

C
the paint surface. If so, please clean it
with water immediately. 3. Dismantle brake pad.

 AUTION: Keep lubricant grease, oil,

C
brake fluid or other dirts from friction
material of brake pad. No stained brake
pad can be installed.
1. Remove wheels and tires.Refer to section
204-04 for more information.
2. Turn up brake caliper.
1 R
 emove one guide bolt at the bottom end of
brake caliper.
● 
Tightening up to 33 ± 5 Nm during insta-
llation. 4. Inspect whether the wear out of brake and
brake disc go beyond limit. Refer to section
206-00 for more information.

 TTENTION: If the friction material has

A
been worn up to or beyond thickness
limit, it is necessary to install a new brake
pad.
5. Inspect whether there is a leakage in brake
caliper.
●  leakage is found, please remove the
If
brake caliper. See this Section for further
information.
6. This installation sequences are contrary to
the dismantling sequences.
7. Inspect brake fluid and fill when necessary.
8. Test working conditions of the brake.

2009.06 Boomday
 Front Disc Brake
206-03-7 206-03-7
Removal and Installation

Brake Caliper
Materials ● Tighten up to 33 ± 5 Nm during installation.

Item Specification
D0T 3 brake fluid SAEJ 1703 or FMVSS 116

Dismantling and Installation

W
 ARNING: The unapproved brake fluids
other than DOT 3 will cause brake to work
improperly. Failure to follow the above
Description may resultin person injury.

C
 AUTION: Do not splash brake fluid onto
the paint surface. If so, please clean it
with water immediately.
4. F or installation, reverse the removal
C
 AUTION: Keep lubricant grease, oil, procedures.
brake fluid or other dirts from friction
material of brake pad. No stained brake 5. Vent air out of brake caliper.Refer to
pad can be installed. section 206-00 for more information.

1. D
 isassemble wheels and tires.Refer to 6. Test working conditions of the brake
section 204-04 for more information. system.

2. R
 emove brake caliper hose fitting bolt, and
take the hose away.
● Discard
 the 2 washers.
● Clamp
 the brake hose with appropriate clip.
● Use
 new washers and tightening the bolt up
to 35 ± 5Nm during installation.

3. R
 emove 2 brake caliper guide bolts and
take down the brake caliper.

2009.06 Boomday
 Front Disc Brake
206-03-8 206-03-8
Removal and Installation

Brake Caliper Mounting Bracket

Removal and Installation
1. Remove wheels and tires.Refer to section
204-04 for more information.
2. Remove two brake caliper guide bolts and
take down the brake caliper.
● Tighten up to 33 ± 5 Nm during installation.

 TTENTION: Do not put brake caliper onto

A
the hose, or the hose will be damaged.

3. Remove brake pad from mounting bracket.

4. Remove two bolts and take down the brake
caliper mounting bracket.
● Tighten up to 158 ± 16 Nm during installation.

5. F or installation, reverse the removal

procedures.

2009.06 Boomday
 Front Disc Brake
206-03-9 206-03-9
Removal and Installation

Brake Disc
Removal and Installation
1. R
 emove wheels and tires.Refer to section
204-04 for more information.
2. R
 emove two bolts, and take down brake
caliper mounting bracket and brake caliper
components.
C
 AUTION: Suspend brake caliper and the
mounting bracket to protect brake hose
from bearing load.
●  ightening up to 158 ± 16 Nm during insta-
T
llation.

3. R
 emove wheel hub and brake disc set.Refer
to section 205-05 for more information.
4. R
 emove brake disc.
● Make
 coincidence marks on brake disc and
wheel hub before dismantling, remove 6 bolts.
● 
Tightening up to 105 ± 10 Nm during insta-
llation.

5. F
 or installation, reverse the removal
procedures.

2009.06 Boomday
 Front Disc Brake
206-03-10 206-03-10
Disassembly and Assembly

Brake Caliper
Disassembly
1. Remove snap ring

2. Remove piston dustproof seal ring.

3. Dismantle break caliper piston.
Item Description  ARNING: Only use appropriate compr-
W
1 Retainer ring essed air when dismantle brake caliper
piston. Never attempt to take the plunger
2 Dustproof seal ring of piston when it is nearly released from p opening.
3 Piston of brake caliper Failure to follow this instruction may
result in personal injury.
4 Piston oil seal
 AUTION: Never use screwdriver or any
C
Materials similar tools to pry the plunger out of
break caliper.
Item Specification
 ut a wood block between brake caliper
1 P
D0T 3 brake fluid SAEJ 1703 or FMVSS 116 body and plunger.
 ill compressed air into brake hose to
2 F
dismantle brake caliper plunger.

4. Remove piston oil seal.

2009.06 Boomday
 Front Disc Brake
206-03-11 206-03-11
Disassembly and Assembly

Assembly

C
 AUTION: If obvious rust, corrosion or
scratch is found on brake caliper opening
or caliper piston, it is necessary to install
a new brake caliper.
1. Install piston oil seal.
● Use
 D0T 3 brake fluid to lubricate piston,
inner wall of caliper piston hole and piston
oil seal before installation.

2. Install brake caliper piston.

● Press
 the piston with hands , never use
hammer or other Knocking tools, or the
piston and inner wall of piston hole will be
damaged.

3. Install dustproof seal ring.

4. Install snap ring.

2009.06 Boomday