Rear

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 C, then remove key plate, push rod and rod.





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





4. Remove return spring, toggle lever and cable guide.

Inspection
CALIPER

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 nuts (M12 x 1.25).





2. Check runout using a dial indicator. Make sure that axial end play is within the specifications before measuring.
3. Change relative positions of rotor and wheel hub so that runout is minimized.
Maximum runout: 0.07 mm (0.0028 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) Maximum 0.02 mm (0.0008 inch)

Assembly





1. Insert cam with depression facing towards open end of cylinder.





2. Generously apply rubber grease to strut and push rod to make insertion easy.





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





4. Install ring C with a suitable tool.








5. Install seat, spring, spring cover and ring B with suitable press and drift.





6. Install cup in the specified direction.





7. Install cup, adjuster, bearing, spacers, washers and ring A with a suitable tool.
8. Insert piston seal into groove on cylinder body.








9. With piston boot fitted to piston, insert piston boot into groove on cylinder body and fit piston by turning it clockwise with long nose pliers, or suitable tool.





10. Fit toggle lever, return spring and cable guide.





11. Adjust the piston to the right angle as shown in the figure.