Rear

REMOVAL





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





1. Remove brake cable mounting bracket bolt and lock spring.
2. Remove torque member fixing bolts and connecting bolt.
It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend caliper assembly with wire so as not to stretch brake hose.


DISASSEMBLY








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





2. Remove ring A from piston with suitable pliers and remove adjusting nut.





3. Disassemble cylinder body.
a. Pry off ring B with suitable pliers, then remove spring cover, spring and seat.
b. Remove ring C, then remove key plate, push rod and strut.





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





4. Remove return spring, cable mounting bracket and parking brake lever.

INSPECTION-CALIPER

CAUTION: Use brake fluid to clean cylinder. Never use mineral oil.

Cylinder Body

- Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body.
- Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper.
Replace cylinder body if necessary.

Torque Member
Check for wear, cracks or other damage. Replace if necessary.

Piston

CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign matter is stuck to sliding surface.

Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above conditions are observed.

Pin and Pin Boot
Check for wear, cracks or other damage. Replace if any of the above conditions are observed.

INSPECTION-ROTOR

Rubbing Surface
Check rotor for roughness, cracks or chips.

Runout

Checking Rotor Runout:

1. Secure rotor to wheel hub with at least two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
Make sure that wheel bearing axial end play is within the specifications before measuring.
3. Change relative positions of rotor and wheel hub so that runout in minimizers.
Maximum runout: 0.07 mm (0.0028 inch)

Thickness





Replace rotor if any of they do not meet specifications.
Rotor repair limit:
Standard thickness 9 mm (0.35 inch)
Minimum thickness 8 mm (031 inch)
Thickness variation (At least 8 positions) Maximum 0.02 mm (0.0008 inch)

ASSEMBLY





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





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





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





4. Install ring C with a suitable tool.





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





6. Install adjusting nut in the specified direction.





7. Install cup, adjusting nut, bearing, spacers, washer and ring A with a suitable tool.








8. Insert piston seal into groove on cylinder body.
9. With dust seal fitted to piston, insert dust seal into groove on cylinder body and fit piston by turning it clockwise with long nose pliers, or suitable tool.





10. Fit parking brake lever, return spring and cable mounting bracket.

INSTALLATION

CAUTION:
- Refill with new brake fluid "DOT 3"
- Never reuse drained brake fluid.

1. Install caliper assembly.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
4. Bleed air.