Rear

Rear Disc Brake





Component

Pad Replacement

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

CAUTION:
- When cylinder body is open, do not depress brake pedal because piston will pop out.
- Be careful not to damage piston boot or get oil on rotor.
Always replace shims in replacing pads.
- If shims are rusted or show peeling of rubber coat, replace them with new shims.
- It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose.
- Burnish the brake contact surfaces after refinishing or replacing drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage.








1. Remove master cylinder reservoir cap.
2. Remove brake cable mounting bolt and lock spring.
3. Release parking brake control lever, then disconnect cable from the caliper.
4. Remove upper pin bolt.
5. Open cylinder body downward. Then remove pad with retainers and inner and outer shims.
Standard pad thickness: 10 mm (0.39 inch)
Pad wear limit: 1.5 mm (0.059 inch)








6. When installing new pads, push piston into cylinder body by gently turning piston clockwise, as shown.
Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.





7. Adjust the piston to the right angle as shown in the figure.





8. As shown in the figure, align the piston's concave portion to the pad's convex portion, then install the cylinder body to the torque member.

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 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.
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. Pry off 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. Pry off ring C, then remove key plate, push rod and rod.





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





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

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.

ROTOR
Rubbing Surface





Check rotor for roughness, cracks or chips.

Runout
1. Secure rotor to wheel hub with two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
Make sure that axial end play is within the specifications before measuring.
3. Change relative positions of rotor and wheel hub so that runout is minimized.
Maximum runout: 0.07 mm (0.0028 inch)
Thickness
Rotor repair limit:
Standard thickness 9 mm (0.35 inch)
Minimum thickness 8 mm (0.315 inch)
Thickness variation (At least 8 portions)
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. Fit push rod into square hole in key plate. Also match convex portion of key plate with concave portion of cylinder.





4. Install ring C with a suitable tool.








5. Install seat, spring, spring cover and ring B with suitable press and drift.





6. Install cup in the specified direction.





7. Install cup, adjuster, bearing, spacers, washers and ring A 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 suitable tool.





10. Fit toggle lever, return spring and cable guide.





11. Adjust the piston to the right angle as shown in the figure.

Installation

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





1. Install caliper assembly.
- Align the piston's concave portion to the pad's convex portion, then install the cylinder body to the torque member.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
4. Bleed air.