Rear

REMOVAL

WARNING: CLEAN BRAKE PADS WITH A VACUUM DUST COLLECTOR TO MINIMIZE THE HAZARD OF AIRBORNE PARTICLES OR OTHER MATERIALS.





1. Remove brake cable mounting bolt and lock spring.
2. Release parking brake control lever, then disconnect cable from the caliper.
3. Remove torque member fixing bolts and connecting bolt.

NOTE: It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend caliper assembly with wire so as not to stretch brake hose.

DISASSEMBLY








1. Remove piston by turning it counterclockwise with suitable commercial service tool or long nose pliers.





2. Pry off ring A from piston with suitable pliers and remove adjusting nut.





3. Disassemble cylinder body.
a. Pry off ring B with suitable pliers, then remove spring cover, spring and seat.
b. Pry off ring then remove key plate, push rod and rod.





c. Remove piston seal. Be careful not to damage cylinder body.





4. Remove return spring, nut and lever.

INSPECTION

CAUTION: Use brake fluid to clean cylinder. Never use mineral oil.

Cylinder Body
- Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body.
- Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.

Torque Member
- Check for wear, cracks or other damage. Replace if necessary.

Piston

CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign matter is stuck to sliding surface.

- Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above conditions are observed.

Pin And Pin Boot
- Check for wear, cracks or other damage. Replace if any of the above conditions are observed.

Rotor

Rubbing surface
- Check rotor for roughness, cracks or chips.

Runout
1. Secure rotor to wheel hub with two (M12 x 1.25) nuts.





2. Check runout using a dial indicator.
Make sure that axial end play is within the specifications before measuring.
End play is 0.05 mm (0.0020 inch)
3. Change relative positions of rotor and wheel hub so that runout is minimized.
Maximum run out is 0.15 mm (0.0059 inch)

Thickness
Rotor repair limit:
Standard thickness: 9 mm (0.35 inch)
Minimum thickness: 8 mm (0.31 inch)
Thickness variation (at least 8 portions): 0.02 mm (0.0008 inch) maximum

ASSEMBLY





1. Install cup in the specified direction.

Positioning Key Plate:

2. Fit push rod into square hole in key plate. Also match convex portion of key plate with concave portion of cylinder.





3. Install ring C with a suitable tool.








4. Install seat, spring, spring cover and ring B with suitable press and drift.
5. Install cup, adjuster, bearing, spacers, washers and ring A with a suitable tool.





6. Fit lever and tighten nut.





7. Fit return spring in the order shown.

INSTALLATION

CAUTION:
- Refill with new brake fluid "DOT 3".
- Never reuse drained brake fluid.

1. Install brake hose to caliper securely.
2. Install all parts and secure all bolts.
3. Bleed air. Refer to Brake Bleeding / Service and Repair / Bleeding Brake System.