Rear

REAR DISC BRAKE





COMPONENTS

REMOVAL (DISC BRAKE PAD)
1. The procedure is the same with front disc brake pad.

DISASSEMBLY (CALIPER)





1. Remove the caliper mounting bolts, and the caliper assembly.
2. Remove the carrier bolt, and the carrier with brake pad.
3. Remove the piston boot.





4. Remove the piston assembly.





5. Remove piston seal with finger tip.

CAUTION: Do not use sharpened tools to prevent damage to the inner surface cylinder.

INSPECTION (DISC BRAKE PAD)





1. Check the pads for wear or oil contamination and replace if necessary.

NOTE: The pads for the right and left wheels should be replaced at the same time.

Pad thickness wear limit: 2.0 mm
2. Check the leading and trailing shoe keys and retaining screw for damage, or wear. Replace the keys and retaining screw at the same time the pads are replaced.
3. Check for worn or damaged dust boots if dust or mud has entered the caliper assembly through this seal, the caliper assembly must be replaced or rebuilt.

INSPECTION (DISC THICKNESS)





1. Using a micrometer, measure disc thickness at eight positions, approximately 45° apart and 10 mm (0.39 inch) in from the outer edge of the disc.
Brake disc thickness
Standard value: 10 mm (0.39 inch)
Limit: 8.4 mm (0.33 inch)
Thickness variation (at least 8 positions)
The difference between any thickness measurements should not be more than 0.01 mm (0.0004 inch).
2. If the disc is beyond the limits for thickness, remove it and install a new one. If thickness variation exceeds the specification, replace the brake disc or turn rotor with an on the car type brake lathe ("MAD. DL-8700PF" or equivalent). Be sure to follow the exact brake lathe manufacturer instructions.

INSPECTION (DISC RUN-OUT)
1. Remove the caliper support bolts, then raise the caliper assembly upward and secure by using wire.
2. Inspect the disc surface for groove, cracks, and rust. Clean the disc thoroughly and remove all rust.





3. Place a dial gauge approximately 5 mm (0.2 inch) from the outer circumference of the brake disc, and measure the runout of the disc.
Limit: 0.03 mm (0.0012 inch)

NOTE: Tighten the nuts in order to secure the disc to the hub.

ASSEMBLY
1. Check for worn, damaged, or rusted piston bore and piston. Replace the damaged parts if necessary.





2. Check for damaged piston seal, boot, and pin insulators.








3. Apply a recommended lubricant to the parts shown.





4. Push the piston into the caliper.





5. Align the piston matching mark to upward as shown in illustration.