Rear

REAR DISC BRAKE





COMPONENTS

OVERHAUL

HINT: Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side.

1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.





3. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)
a. Remove the clip, anti-rattle spring No.1 and anti-rattle spring No.2.
b. Remove the 2 pad guide pins and disc brake pads with anti-squeal shims.
c. Remove the anti-squeal shims from each pad.
4. REMOVE DISC BRAKE CYLINDER ASSEMBLY REAR LH
a. Remove the union bolt and gasket from the disc brake cylinder, then disconnect the flexible hose from the disc brake cylinder.

HINT: Gasket has 2 types: 2-piece type and 1-piece type.





b. Remove the 2 bolts and disc brake cylinder.
5. REMOVE REAR DISC BRAKE CYLINDER MOUNTING COLLAR
a. Remove the 2 cylinder mounting collars from the disc brake cylinder.
6. REMOVE REAR DISC BRAKE BUSH DUST BOOT
a. Remove the 3 bush dust boots.





7. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the set ring and cylinder boot.





8. REMOVE REAR DISC BRAKE PISTON
a. Place a piece of shop rag or equivalent between the piston and the cylinder assembly rear.
b. Use compressed air to remove the piston from the cylinder assembly rear.

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

NOTICE: Do not spatter the brake fluid.





9. REMOVE PISTON SEAL
a. Using a screwdriver, remove the piston seal.

NOTICE: Do not damage the inner cylinder and the cylinder groove.

10. REMOVE REAR DISC BRAKE BLEEDER PLUG
11. INSPECT BRAKE CYLINDER AND PISTON
a. Check the cylinder bore and piston for rust or scoring.





12. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 10.0 mm (0.394 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the pad lining thickness is equal to the minimum thickness or less, replace the disc brake pad kit rear.





13. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 9.0 mm (0.354 inch)
Minimum thickness: 7.5 mm (0.295 inch)
If the disc thickness is less than the minimum, replace the disc.





14. REMOVE REAR DISC
a. Put matchmarks on the rear disc and the axle hub.
b. Remove the rear disc.
15. INSTALL REAR DISC
a. Aligning the matchmarks, install the rear disc.

NOTICE: When replacing the rear disc with a new one, select the installation position where the rear disc has the minimum runout.





16. INSPECT DISC RUNOUT
a. Check the bearing play in the axial direction and check for the axle hub runout.
b. Temporarily fasten the rear disc with hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
c. Using a dial indicator, measure the disc runout 10 mm (0.39 inch) away from the outer edge of the rear disc.
Maximum disc runout: 0.15 mm (0.0059 inch)
If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maximum even when the installation positions are changed, grind the disc. If the disc thickness is less than the minimum, replace the rear disc.
17. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
18. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to a new piston seal.
b. Install the piston seal to the cylinder assembly rear.
19. INSTALL REAR DISC BRAKE PISTON
a. Apply the lithium soap base glycol grease to the piston.
b. Install the piston to the cylinder assembly rear.

NOTICE: Do not screw the piston forcedly in the cylinder.





20. INSTALL CYLINDER BOOT
a. Apply the lithium soap base glycol grease to a new cylinder boot.
b. Install the cylinder boot to the cylinder assembly rear.

HINT: Install the boot securely to the grooves of the cylinder and piston.

c. Using a screwdriver, install the set ring.

NOTICE: Do not damage the cylinder boot.





21. INSTALL REAR DISC BRAKE BUSH DUST BOOT
a. Apply the lithium soap base glycol grease to seal surface of 3 new bush dust boots.
b. Install the 3 bush dust boots to the cylinder assembly rear.
22. INSTALL REAR DISC BRAKE CYLINDER MOUNTING COLLAR
a. Apply the lithium soap base glycol grease to the 2 cylinder mounting collars.
b. Install the 2 cylinder mounting collars.





23. INSTALL DISC BRAKE CYLINDER ASSEMBLY REAR LH
a. Install the cylinder assembly rear with the 2 bolts.
Torque: 46.6 Nm (475 kgf-cm, 34 ft. lbs.)
b. Install a new gasket and flexible hose with the union bolt.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)

NOTICE: Install the flexible hose lock securely into the lock hole in the cylinder assembly rear.

HINT: Gasket has 2 types: 2-piece type and 1-piece type.





24. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY)

NOTICE: When replacing the brake pads, the anti-squeal shims must be replaced together with them.

a. Apply disc brake grease to inside of anti-squeal shims, and install the anti-squeal shims on each pad.
b. Install the inner pad with the pad wear indicator plate facing upward, and install the outer pad.

NOTICE: There should be no oil or grease on the friction surface of the pads and the disc.

c. Install the 2 pad guide pins.





d. Install the anti-rattle spring No.1, anti-rattle spring No.2 and clip.
25. FILL RESERVOIR WITH BRAKE FLUID
26. BLEED MASTER CYLINDER
SST 09023-00101
27. BLEED BRAKE LINE
28. CHECK FLUID LEVEL IN RESERVOIR
29. CHECK FOR BRAKE FLUID LEAKAGE
30. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)