Rear

REAR DISC BRAKE

REMOVAL
1. Remove the wheel.





2. Remove the guide bolt, lift up the caliper assembly, and remove the pad assembly.

DISASSEMBLY SERVICE POINT
Rear disc brakes should be disassembled separately as a set of left and right as a set.





1. Remove the piston boot/piston. Wrap the caliper body with a rag. Blow compressed air into the brake hose, and remove the piston and the piston boot.

CAUTION: Blow air slowly.





2. Remove the piston seal.
1. Remove the piston seal with your finger.

CAUTION: Do not use a screwdriver or another tool in order to avoid damage the inside of the cylinder.

2. Clean the piston surface and the inside of the cylinder using trichloroethylene, alcohol or the specified brake fluid.
Brake fluid: DOT 3 or DOT 4

INSPECTION
1. Check the cylinder for wear, damage and rust.
2. Check the piston surface for wear, damage and rust.
3. Check the caliper body and sleeve for wear.
4. Check that grease is adhesive, and the pad and backing metal are damaged.
5. Check the pads for wear or oil contamination and replace if necessary.

NOTE: The pads for the right and left wheels should be replaced at the same time.





Pad thickness wear limit: 2.0 mm (0.08 inch)

6. Check for worn or damaged dust boots. If dust or mud had entered the caliper assembly through the seal, the caliper assembly must be replaced or repaired.

INSTALLATION
1. Before replacing the brake pads, drain brake fluid from the master cylinder reservoir until it remains half full.








2. Remove the brake pad by turning the piston in the housing assembly. Using the special tool (09581-11000), remove the piston.
3. Install two caliper guide rods and tighten to a torque of 22 - 32 Nm (220 - 320 kg cm, 16 - 23 ft. lbs.)
4. After filling the master cylinder reservoir with the fluid, bleed the brake line.
Recommended brake fluid: DOT 3 or DOT 4

REMOVAL (CALIPER)
1. Remove the rear wheel.
2. Remove the caliper assembly.
3. Remove the brake hose from the caliper.

DISASSEMBLY (CALIPER)
1. Remove the pad.





2. Remove the piston boot from the housing, and then remove the piston.

NOTE: Using a wire hanger or equivalent, remove the caliper so as not to damage the brake hose.





3. Remove the piston by applying compressed air through the brake hose fitting.

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

4. Remove the piston seal carefully so as not to damage the cylinder wall.





5. Clean all removed parts with the specified fluid.





CAUTION: Rubber parts should be replaced with new ones but if you want to reuse them, don't put them in alcohol for more than thirty minutes.

INSPECTION (CALIPER)
1. Check the piston and its inside for wear, damage and rust.
Replace the damaged parts if necessary.





2. Check the piston seal, boot, and pin insulators for wear and damage.

REASSEMBLY (CALIPER)
1. When disassembling the caliper assembly, use a new piston seal and boot.





2. Apply the recommended fluid to the bearing part of the piston seal and piston. Insert the piston seal into grooves inside the caliper, being careful not to twist the seal.





3. Install the piston boot to the piston.
Confirm that the concave part of the piston is placed outward and the boot is seated in grooves of the piston completely.
4. Install the piston and boot in the caliper housing. Insert the boot flange in the caliper housing and check that the boot fits in grooves around the piston.
5. Apply the recommended oil to the inside of the locating pin insulator.

INSTALLATION (CALIPER)
1. Install the caliper mounting bolts.
Tightening torque: 65 - 75 Nm (6.5 - 7.5 kg-m, 47 - 54 ft. lbs.)
2. Refer to "Brake pad installation" for detail.
3. Install the brake hose connector
Tightening torque: 17 - 20 Nm (1.7 - 2.0 kg-m, 12 - 14 ft. lbs.)
4. Install the caliper guide bolt.
Tightening torque: 22 - 32 Nm (2.2 - 3.2 kg-m, 16 - 23 ft. lbs.)
5. Bleed the system.

CAUTION: When replacing the piston seal, check the pedal stroke. If the pedal stroke is too excessive, the piston may not retain the piston seal.

Adjust as follows:
1. After removing the pad from the piston, push the piston into the cylinder 3 - 5 mm. Put a lever or steel plate (l mm x 0.3 m) between the piston and disc, being careful not to damage the contact surface of the disc or the piston end.
2. Install the pad. To restore the brake pedal to the original position, step on it 2-3 times.
3. Repeat the above procedure more than 5 times and move the piston outward and inward to assure that the piston seal is properly installed.
4. Before driving a vehicle, step on the brake pedal and release it several times.
5. Perform the road test