Rear Disc Brake

REAR DISC BRAKE


BRAKE CALIPER ASSEMBLY : Disassembly and Assembly


DISASSEMBLY

NOTE:
Never remove torque member and pad retainers when disassembling and assembling the cylinder body.
1. Remove radius rod. Refer to Exploded View.
2. Remove sliding pin bolts and remove the cylinder body from the torque member.
3. Remove brake pads, shims and shim cover. Refer to Exploded View.
4. Remove sliding pin boots from torque member.
5. Remove bushing from sliding pin bolt.





6. Remove retaining ring (1) from cylinder body using suitable tool as shown in the figure.
7. Place a wooden block as shown in the figure, and blow air from union bolt mounting hole to remove piston and piston boot.






CAUTION:
Never get fingers caught in the piston.
8. Remove piston seal from cylinder body using suitable tool.






CAUTION:
Be careful not to damage a cylinder inner wall.
9. Remove bleeder valve and cap.

ASSEMBLY
1. Install bleeder valve and cap.





2. Apply rubber grease to piston seal (1), and install them to cylinder body.

CAUTION:
Never reuse piston seal.





3. Apply rubber grease to piston boot (1). Cover the piston (2) end with the piston boot, and then install cylinder side lip on the piston boot securely into the groove on cylinder body.

CAUTION:
Never reuse piston boot.





4. Apply brake fluid to piston (1). Push piston into cylinder body by hand and push piston boot (2) piston side lip into the piston groove.

CAUTION:
Press the piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed.





5. Secure piston boot with retaining ring (1).

CAUTION:
- Make sure that boot is securely engaged in the groove on cylinder body.
- Never reuse retainer ring.
6. Apply rubber grease to bushing, and install bushing to sliding pin bolt.
7. Apply rubber grease to sliding pin boots, and install sliding pin boot to torque member.
8. Apply rubber grease to sliding pin bolts, and install the cylinder body to the torque member and tighten the sliding pin bolt to the specified torque.
9. Install radius rod. Refer to Exploded View.