Repair Procedures

REMOVAL

1. Raise the rear of the vehicle and make sure it is securely supported. Remove the rear wheel.
2. Release the parking brake.
3. Remove the guide rod bolt (A). After, raise the caliper assembly (B), and support it with a wire.




4. Remove the pad shim(A) and pad assembly(B).






INSTALLATION

1. Install the pad retainers(A) to the caliper (B).




2. Check the foreign material at the pad shim (A) and the back of the pads (B).




3. Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
4. Install the brake pads (B) and pad shim (A) on the caliper bracket.
5. If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency. Push in the piston using SST(09581-11000) so that the caliper will fit over the pads. Make sure that the piston boot is in position to prevent damaging it when pivoting the caliper down.
6. Pivot caliper down into position. Being careful not to damage the pin boot, install the guide rod bolt (A) and tighten it to the specified torque.




7. Install the brake caliper.
8. After installation, check for leaks at hose and line joints and connections, and retighten if necessary.
9. Depress the brake pedal several times to make sure the brakes work, then test-drive.

NOTE:
Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke.

INSPECTION

REAR BRAKE DISC THICKNESS CHECK
1. Remove all rust and contamination from the disc surface and then measure the disc thickness at 8 positions, minimum.

Rear brake disc thickness
Standard value : 10.0 mm ( 0.39 in)
Limit : 8.0 mm (0.315 in)

2. Thickness variation should not exceed 0.005mm(0.0002 in) (circumference) and 0.01mm(0.0004 in) (radius) at any directions.
3. If wear exceeds the limit, replace the discs and pad assembly for left and right of the vehicle.





REAR BRAKE PAD CHECK
1. Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.

Pad thickness
Standard value : 10.0 mm (0.39 in)
Service limit : 2.0 mm (0.0787 in)




2. Check that grease is applied, and the pad and backing metal for damage.

REAR BRAKE DISC RUN OUT CHECK
1. Place a dial gauge(A) about 5mm (0.2 in) from the outer circumference of the brake disc, and measure the run out of the disc.

Brake disc run out
Limit : 0.03mm (0.0012 in) or less




2. If the run out of the brake disc exceeds the limit specification, replace the disc, and then measure the run out again.
3. If the run out does not exceed the limit specification, install the brake disc after turning it 180° and then check the run out of the brake disc again.
4. If the run out cannot be corrected by changing the position of the brake disc, replace the brake disc.

SEIZE OF REAR BRAKE DISC
1. Remove the brake disc from hub using M8 screw(A) if the brake disc has been seized with the hub due to corrosion or overheat.

NOTE:
Be careful not to use the hammer. The disc can be damaged if you remove the disc from the hub by hammer.