Rear Disc Brake Assembly

DISASSEMBLY
1. Remove the piston boot.





2. Place a wooden block in the caliper body as shown in the figure to prevent the piston from jumping out and being damaged.
3. Gradually apply compressed air via the brake hose installation hole to push the piston out.





4. Remove the piston seal from caliper body cylinder.

CAUTION: Do not damage the cylinder and piston seal groove.





5. Remove the lock pin sleeve and boot from caliper body.
6. Remove the guide pin boot.

ASSEMBLY
1. Clean the inside of the caliper body using brake fluid.
2. Apply a coat of brake fluid to piston seal and install the piston seal to the caliper body groove.
3. Apply a coat of brake fluid to the inner surface of cylinder and the entire outer surface of the piston.
4. Apply grease contained in the piston seal kit to the boot, and install it to the groove at the end of the cylinder.
5. Insert the piston into cylinder.

CAUTION: Do not force the piston into cylinder.

6. Position the boot in the grooves on piston and cylinder.





7. Apply grease contained in the piston seal kit to the guide pin, outer periphery, sleeve periphery, cylinder inner surface, and boot grooves.





8. Insert the guide pin boot to the support.
9. Install the lock pin boot to the support, and then insert the lock pin sleeve into the specified position.

CAUTION: Insert the lock pin and guide pin into position, and make sure that they slide and seat properly.

INSPECTION
1. Repair or replace the faulty parts.
2. Check the caliper body and piston for uneven wear, damage or rust.
3. Check the rubber parts for damage or deterioration.