Rear

REAR BRAKE CALIPER
REMOVAL





1. REMOVE REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
2. DISCONNECT FLEXIBLE HOSE
Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Use a container to catch the brake fluid as it drains out.
Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.)

HINT: At the time of installation, please refer to the following items.
^ Use 2 new gaskets.
^ Install the flexible hose lock securely in the lock hole in the caliper.

3. REMOVE CALIPER
Remove the 2 installation bolts and caliper.
Torque: 44 Nm (449 kgf-cm, 33 ft. lbs.)
4. REMOVE BRAKE PADS
a. Remove the pad protector.
b. Remove the clip and 2 pad guide pins.
c. Remove the anti-rattle spring.
d. Remove the 2 pads with the 4 anti-squeal shims.

DISASSEMBLY





1. REMOVE SET RING AND CYLINDER BOOT
Using a screwdriver, remove the set ring and cylinder boot.





2. REMOVE PISTON
a. Put a piece of cloth or an equivalent between the piston and caliper.
b. Use compressed air to remove the piston from the cylinder.

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





3. REMOVE PISTON SEAL FROM CYLINDER
Using a screwdriver, remove the piston seal.
4. REMOVE 2 SLIDING PINS AND 3 DUST BOOTS

INSPECTION





1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the pad's thickness is at the minimum thickness or less, or if the pad has severe, uneven wear.





2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 9.0 mm (0.354 in.)
Minimum thickness: 8.0 mm (0.317 in.)
Replace the disc if the thickness of the disc is at the minimum thickness or less. Replace the disc or grind it on a lathe if it is scored or worn unevenly.





3. MEASURE DISC RUNOUT
Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the disc.
Maximum disc runout: 0.10 mm (0.0039 in.)
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 or if the disc thickness is not within the specified range, shave the disc. If the disc thickness is less than the minimum, replace the disc.
4. IF NECESSARY, ADJUST DISC RUNOUT
a. Remove the hub nuts and the disc. Turn the disc 1/5 and reinstall the disc. Install and torque the hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Remeasure the disc runout. Make a note of the runout and the disc's position on the hub.
c. Repeat (b) until the disc has been installed on the 3 remaining hub positions.
d. If the minimum runout recorded in (b) and (c) is less than 0.05 mm (0.0020 in.), install the disc in that position.
e. If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 in.), replace the disc and repeat step 3.

REASSEMBLY
Reassembly procedures are disassembly procedures in reverse order.

NOTICE: Before reassembly, apply lithium soap base glycol grease to the parts indicated by the arrows.

INSTALLATION
Installation procedures are removal procedures in reverse order.

HINT:
^ After installation, fill the brake reservoir with brake fluid and bleed the brake system.
^ Check for fluid leaks.