Rear

REAR DISC BRAKE
OVERHAUL

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

1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.

3. DISCONNECT REAR LH FLEXIBLE HOSE
a. Remove the union bolt and the gasket from the cylinder assembly rear, then disconnect the flexible hose.
4. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN
a. Remove the cylinder slide pin (lower).
5. REMOVE DISC BRAKE CYLINDER ASSEMBLY REAR LH
6. REMOVE REAR DISC BRAKE PAD KIT
a. Remove the 2 brake pads w/ antisqueal shims.
7. REMOVE ANTI SQUEAL SHIM KIT REAR
a. Remove the 2 antisqueal shims from each pad.
b. Using a screwdriver, remove the pad wear indicator plate from inner pad.





8. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
a. Remove the 2 pad support plates (No.1) from the cylinder mounting LH.
9. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
a. Remove the 2 pad support plates (No.2) from the cylinder mounting LH.
10. REMOVE REAR DISC BRAKE BUSH DUST BOOT
a. Remove the bush dust boot from the cylinder slide pin (upper).
11. REMOVE REAR DISC BRAKE CYLINDER SLIDE BUSH
a. Remove the cylinder slide bush from the cylinder assembly rear.
12. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN
a. Using a socket hexagon wrench (8 mm), remove the cylinder slide pin (upper).
13. REMOVE REAR DISC BRAKE CYLINDER MOUNTING LH
a. Remove the 2 bolts and the cylinder mounting LH.
14. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the set ring and cylinder boot.





15. REMOVE REAR DISC BRAKE PISTON
a. Place a shop rag between the piston and the cylinder assembly rear.
b. Use compressed air to remove the piston from the cylinder assembly rear.

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

NOTICE: Do not spatter brake fluid.





16. REMOVE PISTON SEAL
a. Using a screwdriver, remove the piston seal from the cylinder assembly rear.

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

17. REMOVE REAR DISC BRAKE BLEEDER PLUG
18. INSPECT BRAKE CYLINDER AND PISTON
a. Inspect the cylinder bore and the brake piston for rust or scoring.
If necessary, replace the disc brake cylinder assembly or piston.





19. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 10.0 mm (0.394 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the pad lining thickness is equal to the minimum thickness or less, replace the disc brake pad kit rear.
20. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE
a. Make sure that they have sufficient rebound, there are no deformation, cracks or wear, and all rust and dirt are cleaned off.
If necessary, replace the rear disc brake pad support plate (No.1).
21. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE
a. Make sure that they have sufficient rebound, there are no deformation, cracks or wear, and all rust and dirt are cleaned off.
If necessary, replace the rear disc brake pad support plate (No.2).





22. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 9.0 mm (0.354 inch)
Minimum thickness: 7.5 mm (0.295 inch)
If the disc thickness is less than the minimum, replace the disc.





23. REMOVE REAR DISC
a. Put matchmarks on the rear disc and the axle hub.
b. Remove the rear disc.
24. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG
25. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG
26. INSTALL REAR DISC
a. Aligning the matchmarks, install the rear disc.

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





27. INSPECT DISC RUNOUT
a. Check the bearing play in the axial direction and check for the axle hub runout.
b. Temporarily fasten the rear disc with hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
c. Using a dial indicator, measure the disc runout 10 mm (0.39 inch) away from the outer edge of the rear disc.
Maximum disc runout: 0.15 mm (0.0059 inch)
If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. 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 rear disc.
28. ADJUST PARKING BRAKE SHOE CLEARANCE
29. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
30. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to a new piston seal.
b. Install the piston seal to the cylinder assembly rear.





31. INSTALL REAR DISC BRAKE PISTON
a. Apply lithium soap base glycol grease to the piston and a new cylinder boot.
b. Install the cylinder boot to the piston.
c. Install the piston w/ cylinder boot to the cylinder assembly rear.

NOTICE: Do not install the piston forcibly in the cylinder assembly.





32. INSTALL CYLINDER BOOT
a. Install the cylinder boot to the cylinder assembly rear.

NOTICE:
- Install the boot securely into the grooves of the cylinder and the piston.
- Do not damage the cylinder boot.

b. Using a screwdriver, install a new set ring.

NOTICE: Do not damage the cylinder boot.

33. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH
a. Install the cylinder mounting LH with the 2 bolts.
Torque: 47 Nm (475 kgf-cm, 34 ft. lbs.)





34. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
a. Apply lithium soap base glycol grease to the sliding part of the cylinder slide pin (upper).
b. Using a socket hexagon wrench (8 mm), install the cylinder slide pin (upper) to the cylinder mounting LH.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)





35. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH
a. Apply lithium soap base glycol grease to the sliding part of a new cylinder slide bush.
b. Install the cylinder slide bush to the cylinder assembly rear.





36. 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 cylinder slide pin (upper).





37. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
a. Install the 2 pad support plates (No.1) to the cylinder mounting LH.
38. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE
a. Install the 2 pad support plates (No.2) to the cylinder mounting LH.





39. INSTALL ANTI SQUEAL SHIM KIT REAR
a. Install the 2 antisqueal shims to the brake pads.

NOTICE: When replacing worn pads, the antisqueal shims must be replaced together with the pads.

b. Install the pad wear indicator plate to the inner pad.

NOTICE: Install the pad wear indicator plate in the correct position and direction.

40. INSTALL REAR DISC BRAKE PAD KIT
a. Install the inner pad to the cylinder mounting LH with pad wear indicator plate facing upward and install the outer pad.

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





41. INSTALL DISC BRAKE CYLINDER ASSEMBLY REAR LH

NOTICE: Make sure that the bush dust boot is installed correctly as shown in the illustration.

42. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
a. Install the cylinder slide pin (lower).
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
43. CONNECT REAR LH FLEXIBLE HOSE
a. Connect the flexible hose with the union bolt and a new gasket.
Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.)
44. FILL RESERVOIR WITH BRAKE FLUID
45. BLEED MASTER CYLINDER
SST 09023-00101
46. BLEED BRAKE LINE
47. CHECK FLUID LEVEL IN RESERVOIR
48. CHECK FOR BRAKE FLUID LEAKAGE
49. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)