Brake pads remove

Replacement of Oil, Oil Filter, Air Filter, Fuel Filter and Spark Plugs (+/- R1200.00 ZAR for parts)
Brake pads has to be inspected and replaced if necessary.
Hand brake has to be checked and adjusted if necessary.
Radiator Coolant level with Anti-Freeze.
Brake Fluid level - Top up if necessary.

Timing Belt, Water pump belt, Air conditioner belt is replaced only every 100000 km.

For 2002 DYNA to replace front brake pads FIRST remove the front master cylinder reservoir cap because as the pistons are pushed back into the caliper the fluid level may rise and you will need to see this and may have to remove some excess fluid, the3n loosen but do not remove both (12 pt/0.25 in.) pad pins, remove both 10 mm caliper mounting bolts, detach and remove the caliper from the front forks and brake disc, pry the pads back to force all four caliper pistons fully into their bores, with the pistons retracted, remove the pad pins and brake pads. The front left, front right (if present as not present on all motorcycles) and the rear brake calipers use the same exact brake pad set. On the right side of the vehicle, the pad with the two tabs installs on the inboard side of the caliper and on the left side the pad with the two tabs installs on the outboard side of the caliper. Install new brakepads into caliper with the curved portion of the pad facing the rear of the motorcycle, loosely install the pad pins until you hear an audible click, attach the caliper to the front fork, on models with dual front calipers check the alignment of the brake discs to the calipers. Loosen the axle pinch bolt nuts, tighten the axle nut to the proper torque, insert a 7/16 in. drill bit through the hole in the axle as far as it will go so that the contact point will have the edge of the drill bit touching the edge of the fork leg, place the caliper over the brake disc with the bleeder valve facing upwards, loosely install the long 12 pt/10 mm mounting bolt into the top hole on the fork leg, install the short 12 pt/10 mm mounting bolt into the bottom hole on the fork leg, tighten the bottom mounting bolt to 28-38 ft-lbs (38.51.5 Nm), final tighten the top mounting bolt to 28-38 ft-lbs (38.51.5 Nm), final tighten both pad pins to 180-200 in-lbs (20.3-22.6 Nm)., on models with dual front calipers, tighten the pinch bolt nuts while holding the slider against the 7/16 drill bit if necessary, remove the drill bit, pump the brake hand lever to move the pistons out until they contact both brake pads, verify the piston location against the pads and if the front wheel is off the ground, rotate it to check for excessive brake pad drag, check the brake fluid level in the master cylinder and fill it to the proper level if necessary using D.O.T. 5 SILICONE BRAKE FLUID, install the master cylinder reservoir cap and tighten its cap screws to 6-8 in-lbs (0.7-0.9 Nm), turn ignition switch ON pump the brake hand lever to verify operation of the brake lamp, test the brakes, test ride the motorcycle and if the brakes feel soft or spongy, bleed the system until you get a firm/hard brake lever and avoid making hard stops for the first 100 miles (160 km) to allow the new brake pads to become conditioned to the brake disc(s).

Hi , what is the solution i have the same issue and i need to solve it as soon as possible.

For 2002 DYNA to replace front brake pads FIRST remove the front master cylinder reservoir cap because as the pistons are pushed back into the caliper the fluid level may rise and you will need to see this and may have to remove some excess fluid, the3n loosen but do not remove both (12 pt/0.25 in.) pad pins, remove both 10 mm caliper mounting bolts, detach and remove the caliper from the front forks and brake disc, pry the pads back to force all four caliper pistons fully into their bores, with the pistons retracted, remove the pad pins and brake pads. The front left, front right (if present as not present on all motorcycles) and the rear brake calipers use the same exact brake pad set. On the right side of the vehicle, the pad with the two tabs installs on the inboard side of the caliper and on the left side the pad with the two tabs installs on the outboard side of the caliper. Install new brake pads into caliper with the curved portion of the pad facing the rear of the motorcycle, loosely install the pad pins until you hear an audible click, attach the caliper to the front fork, on models with dual front calipers check the alignment of the brake discs to the calipers. Loosen the axle pinch bolt nuts, tighten the axle nut to the proper torque, insert a 7/16 in. drill bit through the hole in the axle as far as it will go so that the contact point will have the edge of the drill bit touching the edge of the fork leg, place the caliper over the brake disc with the bleeder valve facing upwards, loosely install the long 12 pt/10 mm mounting bolt into the top hole on the fork leg, install the short 12 pt/10 mm mounting bolt into the bottom hole on the fork leg, tighten the bottom mounting bolt to 28-38 ft-lbs (38.51.5 Nm), final tighten the top mounting bolt to 28-38 ft-lbs (38.51.5 Nm), final tighten both pad pins to 180-200 in-lbs (20.3-22.6 Nm)., on models with dual front calipers, tighten the pinch bolt nuts while holding the slider against the 7/16 drill bit if necessary, remove the drill bit, pump the brake hand lever to move the pistons out until they contact both brake pads, verify the piston location against the pads and if the front wheel is off the ground, rotate it to check for excessive brake pad drag, check the brake fluid level in the master cylinder and fill it to the proper level if necessary using D.O.T. 5 SILICONE BRAKE FLUID, install the master cylinder reservoir cap and tighten its cap screws to 6-8 in-lbs (0.7-0.9 Nm), turn ignition switch ON pump the brake hand lever to verify operation of the brake lamp, test the brakes, test ride the motorcycle and if the brakes feel soft or spongy, bleed the system until you get a firm/hard brake lever and avoid making hard stops for the first 100 miles (160 km) to allow the new brake pads to become conditioned to the brake disc(s

Unbolt the caliper from the front fork.Loosen brake fluid reservoir cap on throttle side of handle bar. Remove the outboard pad ( pad on outside of caliper) and use a 6 inch C clamp to depress piston back into caliper housing. Make sure the clamp presses on the old pad and not directly on the piston end as you might press the piston sideways and scar up the cylinder wall, ruining the caliper. Compress piston until it is flush on the inside case of the caliper. Let sit 5 minutes for the pressure to leak down to keep the piston in place. Remove clamp and inboard pad and replace pads. Remount caliper, tighten bolts and pull the brake lever 5 or 6 times. Check brake fluid level with handlebars straight and top off if necessary.
Hope this helps!!

It can be the wheel Hub bearings. The rotors if warped will wear out pads early. Bad calipers are another possibility as well as a bad Master cylinder.

If the Hub bearings are bad your tires will have cupping. If the tires are okay the rotors are warping from contact with the pads. The pads won't release if the calipers are jamming OR the Master Cylinder is keeping pressure to the calipers.

You can get a pressure check done on the Master cylinder to see if the pressure is releasing when your foot is off the brake. If the pressure is releasing then the calipers are probably sticking. Make sure to use new brake hardware and a lubricate for the hardware when you assemble the calipers.

Maintenance must be carried out at 16 000 km (10 000 miles) or 12-monthly intervals from date of delivery, whichever comes first.

Renew engine oil and oil filter.
Renew drain plug sealing washer.
Renew drain plug assembly.
Visually check underbonnet/underbody
for any fluid leaks.
Inspect brake pads for wear (brake disc
condition on pad change).
Renew coolant.
Renew spark plugs (Normally Aspirated). 112 000 km (70 000 miles)
Renew spark plugs (leaded fuel markets only).
Check accessory drive belt tension wear indicator(s) – replace belt(s) if necessary.
Renew front accessory drive belt. 160 000 km (100 000 miles)
Renew rear accessory drive belt. 112 000 km (70 000 miles)
Check/top-up brake fluid level.
Check/top-up coolant level.
Check/top-up windshield washer reservoir.
Check/top-up power steering fluid level.
Check/top-up battery electrolyte level.

Use a code scanner to get ABS code.

Maintenance: Normal Service 10000 MI or 16000 KM
Check
Brake Pad.............................................................................................................................................................................................. ____
Diagnose/Test
Data Link Connector............................................................................................................................................................................. ____
Check Diagnostic Trouble Code Memory. Purge if necessary, where applicable.
Vehicle.................................................................................................................................................................................................. ____
Road Test - Check braking, kick-down, steering, electrical, heating & ventilation systems, air
conditioning, and power accessories.
Inspect
Battery................................................................................................................................................................................................... ____
Check electrolyte level. Add if necessary.
Brakes and Traction Control................................................................................................................................................................. ____
Check for damage and leaks.
Constant Velocity Joint Boot................................................................................................................................................................ ____
Coolant.................................................................................................................................................................................................. ____
Check fluid level & add if necessary.
Exhaust System..................................................................................................................................................................................... ____
Check for damage and leaks.
Lighting and Horns............................................................................................................................................................................... ____
Check the lights.
Manual Transmission/Transaxle........................................................................................................................................................... ____
Check shift and clutch interlock.
Shift Interlock, A/T (Vehicle with Automatic Shift Lock (ASL).)....................................................................................................... ____
Check operation, including the park/neutral position switch (where applicable).
Tires...................................................................................................................................................................................................... ____
Check condition and pressure, including spare.
Windshield Washer Reservoir.............................................................................................................................................................. ____
Check fluid level & add if necessary.
Lubricate
Doors..................................................................................................................................................................................................... ____
Replace
Engine Oil............................................................................................................................................................................................. ____
Oil Filter, Engine................................................................................................................................................................................... ____
Reset
Service Reminder Indicators...............................................

The hard part is pressing the caliper piston abck into the caliper so you can get the new, thicker pads over the rotor. A large C Clamp works best.

SECTION 206-03: Front Disc Brake 2001 Villager Workshop Manual
REMOVAL AND INSTALLATION Pads —Front Disc Brake Removal

1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04 .

1. Remove the front disc brake caliper bolts. torx bit. T20?

1. Support the front disc brake caliper from the front strut and spring assembly using mechanics wire.

1. Remove the front disc brake pads.
   1. Remove the outboard front disc brake pad.
   1. Remove the inboard front disc brake pad.

Installation

1. CAUTION: Make sure the master cylinder reservoir does not overfill and spill brake fluid while retracting the front disc brake caliper piston.
   NOTE: It is necessary to fully retract the front disc brake caliper piston in the bore before installing the front disc brake pads.
   Install the front disc brake pads.
   1. Install the inboard front disc brake pad.
   1. Install the outboard front disc brake pad.

Caution. The outer pads are left and right. put left on driver side.

1. Position the front disc brake caliper on the front-wheel knuckle and install the brake caliper pin bolts.

1. WARNING: It is necessary to depress the brake pedal several times to position the front disc brake caliper piston before driving the vehicle.