Rear Disc Brakes

CAUTION: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) may come out with force, resulting in serious injury.

NOTICE: Do not use a metal tool to remove the piston seal from the caliper housing bore. Using a metal tool may damage the caliper bore or seal groove.

NOTICE: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the piston out of the bore. If the piston is blown out, even with the padding provided, it may be damaged.

REMOVE OR DISCONNECT
1. Caliper. Refer to "CALIPER."

DISASSEMBLE
1. Piston using compressed air into the caliper inlet hole. Piston will come out through piston boot.





2. Piston ring and piston boot.
- Use a flat blade tool to pry up one end of piston ring. Work piston ring out of caliper groove.
3. Piston seal from groove in caliper body.
- Use a small wooden or plastic tool (not metal) to start piston seal out of caliper bore groove.
4. Bleeder valve from caliper housing.

Clean
- All parts in clean, denatured alcohol. Dry with nonlubricated, low pressure compressed air. Blow out all passages in caliper body and bleeder valve.

Inspect
- Piston for scoring, nicks, cracks, wear or corrosion. Replace piston if any damage is found.
- Piston bore for scoring nicks, wear or corrosion. Use crocus cloth to polish out light corrosion. Otherwise, replace caliper. Do not hone caliper bore.
- Seal groove m caliper bore for nicks or burrs. If found, replace caliper.
- Boots for cuts, tears or deterioration. If damaged, replace boots.
- Caliper bolts for corrosion or damage. Replace corroded or damaged bolts. Do not attempt to polish away corrosion.

ASSEMBLE

NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. the manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

1. Bleeder valve to caliper housing.
- Tighten valve to 11 Nm (97 inch lbs.).
2. Bleeder valve cap.
3. New piston seal into groove in caliper bore.
- Lubricate seal with clean brake fluid.
- Make sure seal is not twisted.
4. Piston boot onto piston.
5. Piston and boot into bore of caliper body.
- Lubricate piston OD with clean brake fluid.
6. Piston ring.
A. Make sure outside edge of piston boot is smoothly seated in counterbore of caliper body.
B. Work piston ring into groove near open end of caliper bore using care not to pinch piston boot between boot ring and caliper body.
C. After installing piston ring, lift inner edge of piston boot next to piston and press out any trapped air. The piston boot must lie flat.

INSTALL OR CONNECT
1. Caliper. Refer to "CALIPER."