Rear

REMOVAL

Exploded View Of Rear Disc Brake Assembly:

WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials.

Rear Disc Fasteners:

1. Remove brake cable mounting bolt and lock spring.
2. Release parking brake control lever, then disconnect cable from the caliper.
3. Remove torque member fixing bolts and connecting bolt.
4. Lift caliper assembly off of rotor.

DISASSEMBLY








1. Remove piston by turning it "counterclockwise" with suitable long nose pliers or commercial service tool.





2. Pry off snap ring from piston with suitable pliers and remove adjusting nut.
3. Disassemble cylinder body, as noted in the following steps:





a. Pry off snap ring with suitable pliers, then remove spring cover, spring and seat.
b. Pry off snap ring then remove key plate, push rod and strut.





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

Return Spring, Toggle Lever And Cable Guide Removal:

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

INSPECTION
Inspect all caliper components. Testing and Inspection

ASSEMBLY





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

Strut And Push Rod Assembly:

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

Positioning Key Plate:

3. Match protrusion on key plate with depression in cylinder.

Snap Ring Assembly:

4. Install snap ring with a suitable tool.





5. Install seat, spring, spring cover and snap ring while depressing with a suitable tool.





6. Install adjuster in direction shown.

Piston Component Installation:

7. Install cup, adjuster, bearing, spacer, wave washer and snap ring 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 equivalent.





10. Fit toggle lever and return spring.

INSTALLATION
1. Install caliper assembly.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
4. Refill with new "DOT 3" brake fluid and bleed air from the hydraulic system. Never reuse drained brake fluid. Service and Repair