Instructions for the Replacement Of Brake Discs

DISMANTLING AND REASSEMBING NEW DISC BRAKE ROTORS 1. Remove the wheel. 2. Remove the pads and draw back the piston/s, using the specific tool (do not lever against the brake rotor). 3. Remove the complete caliper from its support bracket, without disconnecting the fluid feeder hose, making sure that it is not left loosely hanging from the hose itself but, for example, should be secured to the vehicles suspension with a hook. 4. Remove the worn disc. 5. Carefully clean the discs mounting face, taking great care not to soil it with grease or oil as this could jeopardise proper operation of the braking system. Clean the friction surface area ensuring that you only use a non-oil based cleaner i.e. liquid acetone or AKM (DO NOT USE PETROL, KEROSENE or CARBY-CLEANER) 6. Carefully clean the surface of the wheels hub, removing rust and deposits and checking the surface for deformations or damages. 7. Verify that the bearings do not have greater play than the accepted design tolerance and that the ball bearings/rollers are freely running in their respective seats. 8. Assemble the new disc on the hub and, where possible and necessary, proceed to the adjustment of the bearing according to the instructions provided by the manufacturer. Secure the disc-fixing screw without over tightening (if applicable). In the case of a hub type disc (bearing unit incorporated into the disc), tighten the hub nut to the recommended torque setting as outlined by the 9. vehicle manufacturer (refer to the vehicles specification manual). 10. Install the new pads, mounting them correctly in their seats with the relative springs, pins and shims. Where necessary, apply a film of grease correctly on the rear shoulder of the pads. N.B. use exclusively the products suggested by the manufacturer, otherwise serious damage could be caused to the caliper thus generating problems to the whole braking system. 11. After having installed the new disc, assemble the caliper on the support bracket. Check that the dust covers are not damaged and ensure that the caliper slide guides are not excessively worn and slide true and free. 12. Take the piston close to the pads by repeatedly and slowly pumping the brake pedal without reaching full extension. This process will allow the pedal movement to return to normal position. 13. Check the brake fluid level, topping-up to max. Level if necessary. Re-assemble the wheel making sure that the rims are not damaged. Tighten the wheel nuts evenly and in the correct sequence, observing the manufacturers recommended wheel nut torque setting (refer to the Wheel Torque Chart section of this catalogue).

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