Rear

REAR BRAKE





COMPONENTS

OVERHAUL

HINT:
- Use the same procedures for the RH side and LH side.
- The procedures listed below are for the LH side.

1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.





3. DISCONNECT FLEXIBLE HOSE
a. Remove the union bolt and 2 gaskets from the disc brake cylinder assembly rear, then disconnect the flexible hose.





4. REMOVE DISC BRAKE CYLINDER ASSEMBLY REAR LH
a. Remove the 2 cylinder slide pins and disc brake cylinder assembly rear.





5. REMOVE REAR DISC BRAKE CYLINDER SLIDE BUSH
a. Using a screwdriver, remove the cylinder slide bush from the cylinder slide pin (lower).

HINT: Tape the screwdriver tip before use.

6. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)
a. Remove the 2 brake pads with the anti-squeal shims.
7. REMOVE ANTI SQUEAL SHIM KIT REAR
a. Remove the 2 anti-squeal shims from each of the 2 brake pads.
b. Remove the pad wear indicator plate from the inner pad.
8. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
a. Remove the 2 pad support plates from the cylinder mounting LH.





9. REMOVE REAR DISC BRAKE BUSH DUST BOOT
a. Remove the 2 bush dust boots from the cylinder mounting LH.





10. REMOVE REAR DISC BRAKE CYLINDER MOUNTING LH
a. Remove the 2 bolts and cylinder mounting LH.





11. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the set ring and cylinder boot.

NOTICE: Do not damage the piston groove and cylinder groove.

HINT: Tape the screwdriver tip before use.





12. REMOVE REAR DISC BRAKE PISTON
a. Place a shop rag or a piece of cloth between the piston and the disc brake cylinder.
b. Use compressed air to remove the piston from the disc brake cylinder.

CAUTION: Do not place your fingers in front of the piston when using compressed air.

NOTICE: Do not spatter the brake fluid.





13. REMOVE PISTON SEAL
a. Using a screwdriver, remove the piston seal from the brake cylinder.

NOTICE: Do not damage the inner cylinder and the cylinder groove.

HINT: Tape the screwdriver tip before use.
14. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP
15. REMOVE REAR DISC BRAKE BLEEDER PLUG
16. INSPECT BRAKE CYLINDER AND PISTON
a. Check the cylinder bore and piston for rust or scoring.
If necessary. replace the brake cylinder assembly rear and piston.





17. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 10.0 mm (0.394 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the pad lining thickness is equal to or less than the minimum thickness, replace the brake pad.
18. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE
a. Make sure that the pad support plates have sufficient rebound and have no deformation, cracks or wear, and that all rust and dirt is cleaned off.
If necessary, replace the brake pad support plates.





19. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 12.0 mm (0.472 inch)
Minimum thickness: 10.5 mm (0.413 inch)
If the disc thickness is less than the minimum, replace the front disc.
20. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG
21. REMOVE REAR DISC





a. Put matchmarks on the rear disc and the axle hub.





b. Release the parking brake, and remove the rear disc.

HINT: If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely.





22. INSTALL REAR DISC
a. Aligning the matchmarks, install the rear disc.

HINT: When replacing the disc with a new one, select the installation position where the disc has the minimum runout.

23. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG





24. INSPECT DISC RUNOUT
a. Check the bearing play in the axial direction and check for axle hub runout.
b. Temporarily fasten the rear disc with the hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
c. Using a dial indicator, measure the disc runout 10 mm (0.39 inch) from the outer edge of the rear disc.
Maximum disc runout: 0.15 mm (0.0059 inch)
If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maximum even when the installation positions are changed, grind the disc. If the disc thickness is less than the minimum, replace the rear disc.
25. ADJUST PARKING BRAKE SHOE CLEARANCE
26. INSTALL REAR DISC BRAKE BLEEDER PLUG
27. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP
28. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to a new piston seal.
b. Install the piston seal to the disc brake cylinder assembly rear.





29. INSTALL REAR DISC BRAKE PISTON
a. Apply lithium soap base glycol grease to the piston and a new cylinder boot.
b. Install the cylinder boot to the piston.
c. Install the piston to the disc brake cylinder assembly rear.

NOTICE: Do not install the piston forcibly in the cylinder assembly rear.





30. INSTALL CYLINDER BOOT
a. Install the cylinder boot to the disc brake cylinder assembly rear.

NOTICE: Install the cylinder boot securely into the grooves of the cylinder and piston.

b. Using a screwdriver, install a new set ring.

NOTICE:
- Install the set ring securely into the grooves of the cylinder boot.
- Do not damage the cylinder boot.

HINT: Tape the screwdriver tip before use.





31. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH
a. Install the cylinder mounting LH with the 2 bolts.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)





32. INSTALL REAR DISC BRAKE BUSH DUST BOOT
a. Apply lithium soap base glycol grease to the sealing surface of 2 new bush dust boots.
b. Install the 2 bush dust boots to the cylinder mounting LH.
33. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
a. Install the 2 pad support plates to the cylinder mounting LH.





34. INSTALL ANTI SQUEAL SHIM KIT REAR
a. Apply disc brake grease to anti-squeal shim No.1 and No.4 and install them to each pad.

NOTICE:
- When replacing worn pads, replace the anti-squeal shims together with the pads.
- Install the anti-squeal shims in the correct positions and directions.

b. Install anti-squeal shim No.2 and No.3 to each pad.

NOTICE: Install the anti-squeal shims in the correct positions and directions.

c. Install the pad wear indicator plate to the inner pad.

NOTICE: Install the pad wear indicator plate in the correct position and direction.

35. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)
a. Install the 2 brake pads with the anti-squeal shims.

NOTICE:
- There should be no oil or grease on the friction surface of the pads and the disc.
- Install the inner load with indicator elate facing downward.





36. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH
a. Apply lithium soap base glycol grease to a new cylinder slide bush.
b. Install the cylinder slide bush to the cylinder slide pin (lower).





37. INSTALL DISC BRAKE CYLINDER ASSEMBLY REAR LH
a. Apply lithium soap base glycol grease to the sliding part and the seal surfaces of the cylinder slide pins.
b. Install the disc brake cylinder assembly rear with the 2 cylinder slide pins.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)





38. CONNECT FLEXIBLE HOSE
a. Connect the flexible hose with the union bolt and 2 new gaskets.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)

NOTICE: Install the flexible hose lock securely in the lock hole in the disc brake cylinder assembly rear.

39. FILL RESERVOIR WITH BRAKE FLUID
40. BLEED BRAKE LINE
41. CHECK FLUID LEVEL IN RESERVOIR
42. CHECK BRAKE FLUID LEAKAGE
43. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)