Rear brake

Components Removal / installation

REAR BRAKE

EXPLODED VIEW

REMOVAL

NOTE:

·The following procedure is for LH side.
·Perform the same procedures for the RH and LH side.

1. Removal of rear tire

2. Draining of brake fluid

CAUTION:

Do not let brake fluid come into contact with the painted surface. If it happens, wash it out immediately.

3. Disconnection of rear left flexible hose

(1) Remove the union bolt and 2 gaskets to disconnect the rear left flexible hose from the disk brake cylinder ASSY RR LH.

Captions in illustration

*A	Solid disc brake
*B	Ventilated disc brake

4. Removal of disc brake cylinder ASSY RR LH

(1) Remove 2 bolts and then the disc brake cylinder ASSY RR LH.

5. Removal of disc brake pad kit RR

(1) Remove the disc brake pad kit RR from the rear disc brake cylinder mounting LH.

Captions in illustration

*A	Solid disc brake
*B	Ventilated disc brake

6. Removal of rear disc brake anti squeal shim kit

(1) Remove the rear disc brake anti-squeal shim kit from the disc brake pad kit RR.

Captions in illustration

*A	Solid disc brake
*B	Ventilated disc brake
*1	Disc brake pad kit RR
*2	Rear disc brake anti squeal shim kit

7. Removal of pad clip

(1) Remove the pad clip.

8. Removal of rear disc brake cylinder mounting LH

(1) Remove 2 bolts and then the rear disc brake cylinder mounting LH.

9. Removal of parking brake shoe adjusting hole plug

Remove the parking brake shoe adjusting hole plug from the rear disc.

10. Removal of rear disc

(1) Put alignment marks on the rear disc and rear axle hub. (This is not required when replacing the rear disc.)

Captions in illustration

*a	Alignment marks

(2) Release the parking brake and remove the rear disc.

NOTE:

If it is difficult to remove the rear disc, insert a flat head screwdriver from the rear disc service hole and rotate the adjusting screw to contract the parking brake shoe.

Captions in illustration

*a	Contract
*b	Extend

11. Removal of slide pin

(1) Remove the slide pin from the rear disc brake cylinder mounting LH.

12. Removal of slide lock pin

(1) Remove the slide lock pin from the rear disc brake cylinder mounting LH.

(2) Remove the bushing from the slide lock pin.

13. Removal of rear disc brake bushing dust boot

(1) Remove 2 rear disc brake bushing dust boots from the rear disc brake cylinder mounting LH.

DISASSEMBLY

1. Removal of rear disc brake piston

(1) Put a wooden block between the rear disc brake piston and the disc brake cylinder to prevent the rear disc brake piston from being damaged.

Captions in illustration

*1	Wooden block
*a	30mm {1.181in}

(2) Using an air gun, gradually blow air into the applicable part to remove the rear disc brake piston.

WARNING:

Be careful not to pinch your fingers.

CAUTION:

Be careful not to spill brake fluid.

2. Removal of cylinder boot

(1) Using a thin flat tip screwdriver, remove the cylinder boot from the disc brake cylinder.

NOTE:

Wrap the tip of the screwdriver with a protective tape.

CAUTION:

Do not damage the cylinder wall and the piston seal groove.

Captions in illustration

*1	Protective tape

3. Removal of piston seal

(1) Using a thin flat tip screwdriver, remove the piston seal.

NOTE:

Wrap the tip of the screwdriver with a protective tape.

CAUTION:

Do not damage the cylinder wall and the piston seal groove.

Captions in illustration

*1	Protective tape

4. Removal of rear disc brake bleeder plug cap

(1) Remove the rear disc brake bleeder plug cap from the rear disc brake bleeder plug.

5. Removal of rear disc brake bleeder plug

(1) Remove the rear disc brake bleeder plug from the disc brake cylinder ASSY RR LH.

INSPECTION

1. Disc brake piston and cylinder check

(1) Check that there is no damage on the side of the disc brake piston and on the disc brake cylinder wall.

2. Disc brake pad thickness check

Specifications	Limit	New (reference):
Solid type	1.5mm {0.059in}	9.0mm {0.354in}
Ventilated type	1.5mm {0.059in}	11.0mm {0.433in}

3. Disc thickness check

Specifications	Limit	New (reference):
Solid type	8.5mm {0.335in}	10.0mm {0.394in}
Ventilated type	16.0mm {0.63in}	18.0mm {0.709in}

4. Disc runout check

(1) Before checking the rear disc runout, check the rear axle hub bearing play (Refer to

) and runout (Refer to

(2) Secure the rear disc with 5 hub nuts.

Standard value:

Tightening torque=120N·m { 1224kgf·cm} {88.5ft·lbf}

(3) Using a dial gauge, check the runout 10 mm {0.394 in} inside from the outer periphery of the rear disc.

Captions in illustration

*1	Dial gauge

Limit : 0.05mm {0.002in}

CAUTION:

When the runout exceeds the limit, change the positions of the rear disc and rear axle hub to minimize the runout before installation. If the runout still exceeds the limit even after changing the rear disc and the rear axle hub positions, replace the rear disc with new one.

ASSEMBLY

1. Temporarily tightening of rear disc brake bleeder plug

(1) Temporarily tighten the rear disc brake bleeder plug to the disc brake cylinder ASSY RR LH.

2. Installation of rear disc brake bleeder plug cap

(1) Install the rear disc brake bleeder plug cap to the rear disc brake bleeder plug.

3. Installation of piston seal

(1) Apply rubber grease (RENOLIT rubber grease JP) or equivalent to a new piston seal and install it in the disc brake cylinder groove.

Captions in illustration

Rubber grease (RENOLIT rubber grease JP) or equivalent

4. Installation of cylinder boot

(1) Apply rubber grease (RENOLIT rubber grease JP) or equivalent to the outer periphery of the disc brake piston.

Captions in illustration

*1	Piston
*2	Cylinder boot
	Rubber grease (RENOLIT rubber grease JP) or equivalent

(2) Apply rubber grease (RENOLIT rubber grease JP) or equivalent to a new cylinder boot and install it to the bottom of the disc brake piston as shown in the figure.

5. Installation of rear disc brake piston

(1) Attach the seal portion of the cylinder boot to the disc brake cylinder groove.

Captions in illustration

*1	Cylinder boot
*2	Piston
*3	Cylinder

CAUTION:

Make sure that the seal portion of the cylinder boot is securely attached.

(2) Push in the piston by hand, and attach the seal portion of the boot to the piston groove.

CAUTION:

Make sure that the seal portion of the cylinder boot is securely attached.

INSTALLATION

NOTE:

·The following procedure is for LH side.
·Service the LH side and the RH side using the same procedure.

1. Installation of rear disc brake bushing duct boot

(1) Apply rubber grease (NIGLUBE RX-2) or equivalent inside a new rear disc brake bushing dust boot.

Captions in illustration

Rubber grease (NIGLUBE RX-2) or equivalent

NOTE:

Apply 1.5±0.2 g {0.05±0.007} or more of rubber grease (NIGLUBE RX-2) or equivalent per 1 rear disc brake bushing dust boot.

(2) Install 2 rear disc brake bushing dust boots to the rear disc brake cylinder mounting LH.

2. Installation of slide lock pin

(1) Apply rubber grease (NIGLUBE RX-2) or equivalent to the contacting surface of the new bushing and the slide lock pin.

Captions in illustration

*1	Slide lock pin
*2	Bushing
	Rubber grease (NIGLUBE RX-2) or equivalent

(2) Install the bushing to the slide lock pin.

(3) Apply rubber grease (NIGLUBE RX-2) or equivalent to the sliding part and the engaging part of the slide lock pin.

(4) Install the slide lock pin to the rear disc brake cylinder mounting LH.

3. Installation of slide pin

(1) Apply rubber grease (NIGLUBE RX-2) or equivalent to the sliding part and the engaging part of the slide pin.

Captions in illustration

Rubber grease (NIGLUBE RX-2) or equivalent

(2) Install the slide pin to the rear disc brake cylinder mounting LH.

4. Installation of rear disc

(1) Aligning the mark which you put at the time of removal, install the rear disc to the axle hub.

NOTE:

When replacing the rear disc with new one, select the position where the rear disc runout becomes the minimum and install it.

5. Clearance adjustment of disc and lining (Refer to

)

6. Installation of parking brake shoe adjusting hole plug

(1) Install the parking brake shoe adjusting hole plug to the rear disc.

7. Installation of rear disc brake cylinder mounting LH

(1) Install the rear disc brake cylinder mounting LH with 2 new bolts.

Standard value:

Tightening torque=66N·m { 673kgf·cm} {48.7ft·lbf}

(2) Apply a thin coat of MP grease No.2 (BG-401) or equivalent to the contacting part of the rear disc brake cylinder mounting LH and the pad clip.

Captions in illustration

MP grease No.2 (BG-401) or equivalent

8. Installation of pad clip

(1) Apply a thin coat of MP grease No.2 (BG-401) or equivalent to the part where the disc brake pad kit RR of the pad clip contacts.

Captions in illustration

MP grease No.2 (BG-401) or equivalent

(2) Install the pad clip to the rear disc brake cylinder mounting LH.

9. Installation of rear disc brake anti-squeal shim kit

(1) Apply disc brake grease II to the rear disc brake anti-squeal shim kit.

Captions in illustration

*A	Solid disc brake
*B	Ventilated disc brake
*1	Disc brake pad kit RR
*2	Rear disc brake anti-squeal shim kit
	Disc brake grease II (BG-402) or equivalent

(2) Install the rear disc brake anti-squeal shim kit to the disc brake pad kit RR.

10. Installation of disc brake pad kit RR

(1) Install the disc brake pad kit RR to the rear disc brake cylinder mounting LH.

11. Installation of disc brake cylinder ASSY RR LH

(1) Install the disc brake cylinder ASSY RR LH to the rear disc brake cylinder mounting LH with 2 bolts.

Standard value:

Tightening torque=26N·m { 265kgf·cm} {19.2ft·lbf}

12. Connection of rear left flexible hose

(1) Using a new union bolt, connect the rear left flexible hose via 2 new gaskets.

Standard value:

Tightening torque=18N·m { 184kgf·cm} {13.3ft·lbf}

13. Brake fluid refill (Refer to

)

14. Air bleeding of brake system (Refer to

)

15. Brake fluid leak check

16. Brake fluid level check (Refer to

)

17. Installation of rear tire

Standard value:

Tightening torque=120N·m { 1224kgf·cm} {88.5ft·lbf}