Rear

REAR DISC BRAKE





COMPONENTS

REMOVAL
CALIPER ASSEMBLY
1. Remove the wheel and tire.





2. Disconnect the brake hose.

CAUTION:
- Do not spell brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.
- To prevent spills, plug the hose inlets with rags or shop towels.





3. Remove the cylinder mounting bolt.





4. Remove cylinder and pads from the caliper bracket.
5. Remove the caliper mounting bolts from the knuckle.





6. Remove the caliper mounting bracket.

DISASSEMBLY
1. Remove the piston boot.
2. Remove the piston using compressed air.





NOTE:
1. Do not put your fingers in front of the piston when using compressed air.
2. Be careful not to splatter the brake fluid.





3. Remove the piston seal with finger tip.

CAUTION: Take care not to damage the piston wall surface.

INSPECTION
1. Check the caliper for wear, damage, cracks and dust.
2. Check the piston for dust, damage, cracks and wear on the outer surface.
3. Check the sleeve and pin for damage and dust.
4. Check the pad spring and boots for damage.
5. Check the carrier for damage, dust, wear and cracks.

CAUTION:
1. Do not use sand paper on the piston surface.
2. All rubber parts must be replaced with new parts.





6. Inspect the disc by using a caliper and a dial gauge.
Thickness of disc mm (inch)
Standard value: 10 (0.39)
Service limit: 8.4 (0.33)
Runout of the disc mm (inch): 0.03 (0.0012)
Difference of thickness mm (inch): 0.01 (0.0004)

NOTE:
1. Using a micrometer, measure the disc thickness at eight positions approximately 10mm from the outer edge of the disc and at 45° intervals.
If you subtract the minimum of measurements from the maximum, you get the difference of the disc thickness.
2. When measuring the disc runout, fix a dial gauge approximately 5 mm from the outer edge of the disc, and rotate the disc 360°.
At this time, if you subtract the minimum of measurements from the maximum, you get the disc runout.

7. If necessary, replace the brake disc.

REASSEMBLY
1. Check for worn, damaged, or rusted piston bore and piston. Replace the damaged parts if necessary.
2. Check for damaged piston seal, boot and pin insulators.








3. Apply the recommended fluid to the following parts.





4. Push the piston into the caliper.





5. Position the piston matchmarks on the upper side so that they are located in a straight line with the piston.

INSTALLATION
CALIPER ASSEMBLY
Installation is the reverse of removal.
1. Be careful not to spill grease or oil on the pad and brake disconcert surface.
2. Tighten the caliper mounting bolt to the specified torque.





3. Install the brake hose.





4. Bleed the system.