Rear Disc Brake Disassembly and Assembly

Rear Disc Brake: Disassembly and Assembly

Disassembly

1) Remove the caliper body from the torque member. Refer to [Rear Brake Caliper and Disc Rotor: Removal and Installation] Rear Brake Caliper and Disc Rotor.
2) Remove the sliding pins and boots from the torque member.
3) Place a wooden block in the cylinder body and blow air into the union bolt hole to remove the piston and piston boot as shown.






WARNING:
Do not get your fingers caught between the piston and wooden block.

4) Remove the piston boot from the piston.

CAUTION:
Do not reuse piston boot.

5) Remove piston seal from cylinder body, using a suitable tool.






CAUTION:
Be careful not to damage cylinder body inner wall.

6) Remove the bleed valve and cap.

Caliper Inspection

Cylinder Body

- Check inside surface of cylinder for score, rust wear, damage or 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.

CAUTION:

- Use new brake fluid for cleaning. Do not use mineral oils such as gasoline or kerosene.

Torque Member

Check the torque member for wear, cracks, and damage. If damage or deformation is present, replace the torque member.

Piston

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

CAUTION:

Piston sliding surface is plated, do not polish with emery paper even if rust or foreign materials are stuck to sliding surface.

Sliding Pin Bolts and Sliding Pin Boots

Check the sliding pins and sliding pin boots for wear, damage, and cracks. If damage or deformation is present, replace the affected part.

Assembly

CAUTION:

Use rubber grease when assembling.

1) Install the bleed valve and cap.
2) Apply rubber grease to the new piston seal (1) and insert the new piston seal (1) into the groove on the cylinder body.






CAUTION:
Do not reuse piston seal.

3) Apply rubber grease to the new piston boot (1). Cover the piston end (2) with the piston boot (1), and then install the cylinder side lip on the piston boot (1) securely into the groove on the cylinder body.






CAUTION:
- Do not reuse piston boot.
- Press pistons in evenly and vary the pressing points to prevent the cylinder inner wall from being damaged.

4) Install the piston (1) into the cylinder body and insert the piston boot (2) side lip into the piston groove as shown.






CAUTION:
Press pistons in evenly and vary the pressing points to prevent the cylinder inner wall from being damaged.

5) Apply rubber grease to the sliding pin boots, then install sliding pins and sliding pin boots on the torque member.
6) Install the caliper body on the torque member. Refer to [Rear Brake Caliper and Disc Rotor: Removal and Installation] Rear Brake Caliper and Disc Rotor.