Rear

REAR BRAKE

COMPONENTS (Part 1):

COMPONENTS (Part 2):

DISASSEMBLY





1. REMOVE CALIPER SUPPORT BRACKET
(a) Remove the caliper support bracket from the rear disc brake cylinder.

2. REMOVE REAR DISC BRAKE CYLINDER SLIDE BUSH
(a) Remove the cylinder slide bush from the rear disc brake cylinder.

3. REMOVE REAR DISC BRAKE BUSH DUST BOOT
(a) Remove the bush dust boot from the rear disc brake cylinder.





4. REMOVE REAR DISC BRAKE PISTON
(a) Place a piece of cloth between the piston and the rear disc brake cylinder.
(b) Use compressed air to remove the piston from the rear disc brake cylinder.

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

NOTICE: Do not spatter the brake fluid.

5. REMOVE CYLINDER BOOT
(a) Remove the cylinder boot from the piston or rear disc brake cylinder.





6. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal from the rear disc brake cylinder.

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

HINT: Tape the screwdriver tip before using.

7. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP
8. REMOVE REAR DISC BRAKE BLEEDER PLUG





9. REMOVE REAR DISC
(a) Put matchmarks on the rear disc and the axle hub.
(b) Remove the rear disc.

10. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG

REASSEMBLY
1. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG





2. INSTALL REAR DISC
(a) Aligning the matchmarks, install the rear disc.

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

3. ADJUST PARKING BRAKE SHOE CLEARANCE
(a) Adjust the parking brake shoe clearance.

4. TEMPORARILY INSTALL REAR DISC BRAKE BLEEDER PLUG
5. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP





6. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the rear disc brake cylinder.

7. INSTALL CYLINDER BOOT
(a) Apply lithium soap base glycol grease to the piston and a new cylinder boot.
(b) Install the cylinder boot to the piston.





8. INSTALL REAR DISC BRAKE PISTON
(a) Install the cylinder boot to the rear disc brake cylinder.

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

(b) Push in the piston by hand and install the boot seal onto the grooves of the piston.

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





9. 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 rear disc brake cylinder.

NOTICE: Install the cylinder slide bush securely to the grooves of the rear disc brake cylinder.





10. INSTALL REAR DISC BRAKE BUSH DUST BOOT
(a) Apply lithium soap base glycol grease to a new bush dust boot.
(b) Install the bush dust boot to the rear disc brake cylinder.

NOTICE: Install the bush dust boot securely to the grooves of the rear disc brake cylinder.





11. INSTALL CALIPER SUPPORT BRACKET
(a) Apply lithium soap base glycol grease to the caliper support bracket.
(b) Install the caliper support bracket to the rear disc brake cylinder.

NOTICE: Install the bush dust boot securely to the grooves of the caliper support bracket.