Removal And Installation

REAR DISC BRAKE

Removal and Installation of Brake Caliper and Rotor


WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne particles or other materials.

CAUTION:
- While removing and installing the cylinder body, do not depress the brake pedal because the piston will pop out.
- Do not damage the piston boot.
- Keep rotor free from grease and brake fluid.
- Refill the brake reservoir with new brake fluid.
- Never reuse drained brake fluid.
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.

REMOVAL

1.Remove the rear wheel and tire.
2.Hold the disc rotor in place by installing a wheel nut.
3.Remove the reservoir cap.





4.Remove the union bolt and copper sealing washers, then disconnect the brake hose from the cylinder body. Discard the copper sealing washers.

CAUTION:
Do not reuse copper sealing washers.
5.Remove the torque member bolts, and remove the brake caliper assembly.

CAUTION:
Do not drop brake the pads.





6.Remove the disc rotor. If reusing the disc rotor, before removing the disc rotor apply matching mark as shown.

CAUTION:
Put matching marks on wheel hub assembly and disc rotor, if reusing the disc rotor.

INSTALLATION






1.Install the disc rotor. If reusing the disc rotor, align the matching mark to position the disc rotor on the wheel hub assembly.

CAUTION:
Align the matching mark on wheel hub assembly and disc rotor, if reusing the disc rotor.
2.Install the brake caliper assembly, and tighten the torque member bolts to the specified torque.

CAUTION:
Before installing caliper assembly, wipe off oil and moisture on all mounting surfaces of rear axle and caliper assembly and threads, bolts and washers.





3.Install the brake hose with two new copper sealing washers (1), using the L-shaped pin for alignment as shown, then tighten the union bolt (A) to the specified torque.

CAUTION:
Do not reuse copper sealing washers.
4.Refill the brake hydraulic system with new brake fluid and bleed brake system. Service and Repair.
5.Check the rear disc brakes for drag.
6.Install the rear wheel and tire. Adjustment.