Rear Brake

OVERHAUL

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

1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Wash off brake fluid immediately if it comes in contact with any painted surface.





3. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)
a. Using your fingers, pull the part labeled B away from the brake cylinder. Then push up the part labeled A and detach the No. 1 anti-squeal spring from the brake cylinder.
b. Remove the No. 1 spring.

NOTICE:
^ Do not deform the clip and spring.
^ The clip and spring can be used again provided that they have sufficient tension; no deformation, cracks or wear; and have no rust, dirt or foreign matter.

c. Remove the No. 2 anti-squeal spring.
d. Remove the clip and pad guide pin.
e. Remove the 2 pads.
f. Remove the 4 anti-squeal shims from each pad.
4. REMOVE DISC BRAKE CYLINDER ASSEMBLY REAR LH
a. Remove the union bolt and gasket from the cylinder, then disconnect the flexible hose from the cylinder.
b. Remove the 2 bolts and cylinder.





5. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the 2 set rings and boots.

NOTICE: Be careful not to damage the brake piston and cylinder.





6. REMOVE REAR DISC BRAKE PISTON
a. Prepare a wooden block as shown in the illustration.





b. Place the block between the pistons. Then insert a pad on one side of the wood.
c. Use compressed air to remove the 2 pistons alternately from the cylinder.

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

NOTICE: Be careful not to spatter the brake fluid.





7. REMOVE PISTON SEAL
a. Using a screwdriver, pry out the 2 seals from the cylinder.

NOTICE: Be careful not to damage the inner cylinder and the cylinder groove.

8. REMOVE REAR DISC BRAKE BLEEDER PLUG
9. INSPECT BRAKE CYLINDER AND PISTON
a. Check the cylinder bore and piston for rust or scoring.
If necessary, replace the cylinder and piston.





10. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 10.5 mm (0.413 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the pad lining thickness is equal to or less than the minimum, replace the pad.





11. 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 disc.
12. REMOVE REAR DISC
a. Put matchmarks on the disc and the axle hub.
b. Remove the disc.
13. INSTALL REAR DISC
a. Align the matchmarks and install the disc.

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





14. INSPECT DISC RUNOUT
a. Check the bearing play in the axial direction and check the axle hub runout.
b. Temporarily fasten the disc with hub nuts.
c. Using dial indicator, measure the disc runout 10 mm (0.39 inch) away from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 inch)
If the runout is greater than the maximum, change the installation positions of the disc and axle so that the runout is as small as possible.
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 disc.
d. Install the 2 hub nuts.
15. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
a. Install the bleeder plug to the cylinder.

HINT: The bleeder plug will be tighten to a torque specification in step 23.

16. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to the 2 seals.
b. Install the 2 seals to the cylinder.
17. INSTALL REAR DISC BRAKE PISTON
a. Apply lithium soap base glycol grease to the 2 pistons.
b. Install the 2 pistons to the cylinder.

NOTICE: Do not install the piston forcibly to the cylinder.

18. INSTALL CYLINDER BOOT
a. Apply lithium soap base glycol grease on the 2 boots.
b. Install the 2 boots to the cylinder.

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

c. Using a screwdriver, install the 2 set rings.

NOTICE: Be careful not to damage the cylinder boot.

19. INSTALL DISC BRAKE CYLINDER ASSEMBLY REAR LH
a. Install the cylinder with the 2 bolts.
Torque: 104 Nm (1,065 kgf-cm, 77 ft. lbs.)
b. Install a new gasket and flexible hose with the union bolt.
Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.)
20. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)
a. Apply disc brake grease to both sides of the inner antisqueal shims.





b. Install the 2 shims on each pad.

NOTICE:
^ When replacing a worn pad, the shims must be replaced together with the pads.
^ Make sure the arrows on the inner shims face the direction of disc rotation, as shown in the illustration.

c. Drain a small amount of fluid from the reservoir.





d. Press in the pistons with a wrench's handle or equivalent.

HINT:
^ Tape the wrench's handle before use.
^ If the piston is difficult to push in, loosen the bleeder plug and push in the piston while draining some fluid.

e. Install the 2 pads.

NOTICE: There should be no oil or grease on the friction surface of the pads and disc.

f. Install the pad guide pin and clip.





g. Install a new No. 2 spring.





h. Install the No. 1 spring.

HINT:
^ Ensure that the claw of the spring is raised up on the cylinder securely.
^ Ensure that there is no gap between the pad guide pin and spring.
^ Ensure that A and B portions of the spring are attached to the pad.

21. FILL RESERVOIR WITH BRAKE FLUID
22. BLEED AIR FROM MASTER CYLINDER
23. BLEED AIR FROM BRAKE LINE
24. CHECK FLUID LEVEL IN RESERVOIR
25. CHECK BRAKE FLUID LEAKAGE
26. Install REAR WHEEL
a. Install the wheel with the 5 nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Install the ornament with the 10 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)