REAR BRAKE

Removing the rear brake caliper

Order

Job/Parts to remove

Q’ty

Remarks

 

Brake fluid

 

Drain.

Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM.

 

Rear wheel

 

Refer to REAR WHEEL.

1

Protector

1

 

2

Union bolt

1

 

3

Copper washer

2

 

4

Rear brake hose

1

 

Removing the rear brake caliper

Order

Job/Parts to remove

Q’ty

Remarks

5

Brake pad pin plug

1

 

6

Brake pad pin

1

 

7

Rear brake pad assembly

2

 

8

Rear brake caliper bracket

1

 

9

Brake pad spring

1

 

10

Brake pad spring

1

 

11

Rear brake caliper assembly

1

 

12

Rear brake disc cover

1

 

Disassembling the rear brake caliper

Order

Job/Parts to remove

Q’ty

Remarks

1

Brake caliper piston

1

 

2

Brake caliper piston dust seal

1

 

3

Brake caliper piston seal

1

 

4

Bleed screw

1

 

Removing the rear brake master cylinder

Order

Job/Parts to remove

Q’ty

Remarks

 

Brake fluid

 

Drain.

Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM.

1

Union bolt

1

 

2

Copper washer

2

 

3

Brake hose

1

 

Removing the rear brake master cylinder

Order

Job/Parts to remove

Q’ty

Remarks

4

Split pin

1

 

5

Washer

1

 

6

Pin

1

 

7

Brake master cylinder reservoir cap

1

 

8

Brake master cylinder reservoir diaphragm plate

1

 

9

Brake master cylinder reservoir diaphragm

1

 

10

Rear brake master cylinder

1

 

Disassembling the rear brake master cylinder

Order

Job/Parts to remove

Q’ty

Remarks

1

Brake master cylinder joint

1

 

2

Brake master cylinder kit

1

 

INTRODUCTION

If you need to disassemble the disc brake components, observe the following precautions.

  • Never disassemble the brake components unless absolutely necessary.

  • If there is any problem with connections on the hydraulic brake system, perform the following jobs. Disassemble the brake system, drain the brake fluid, and clean it. After that, add a suitable amount of brake fluid. Then, bleed it after reassembly.

  • Use only brake fluid for washing internal brake components.

  • Use new brake fluid for cleaning the brake components.

  • Immediately wipe off the spilled brake fluid to avoid damage to painted surfaces or plastic parts.

  • Handle brake fluid with special care not to let it enter your eyes so that you may not lost your eyesight.

  • FIRST AID FOR BRAKE FLUID ENTERING THE EYES:

  • Flush with water for 15 minutes and get immediate medical attention.

CHECKING THE REAR BRAKE DISC

1.Check:

  • Brake disc

    Damage/galling → Replace.

2.Measure:

  • Brake disc thickness

    Measure the brake disc thickness at a few different locations.

    Out of specification → Replace.

    Refer to CHECKING THE FRONT BRAKE DISC.

  • Brake disc thickness limit

    3.5 mm (0.14 in)

3.Measure:

  • Brake disc runout limit (as measured on wheel)

    0.15 mm (0.0059 in)

4.Replace:

REPLACING THE REAR BRAKE PADS

When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.

1.Remove:

  • Brake pad

a.Remove the protector “1” and the pad pin plug “2”.

b.Loosen the pad pin “3”.

c.Remove the rear wheel “4” and the brake caliper “5”.

Refer to REAR WHEEL.

d.Remove the pad pin “6” and the brake pads “7”.

2.Measure:

  • Brake pad wear limit “a”

    Out of specification → Replace the brake pads as a set.

  • Brake pad lining thickness limit

    1.0 mm (0.04 in)

3.Install:

  • Brake pad

a.Connect the plastic hose “1” to the bleed screw “2” and place a container under the end of the plastic hose.

b.Loosen the bleed screw and push the brake caliper piston in.

Do not reuse the drained brake fluid.

c.Tighten the bleed screw.

  • Bleed screw

    5 N·m (0.5 kgf·m, 3.7 lb·ft)

d.Install the brake pads “3” and the pad pin “4”.

  • Install the brake pads with their projections “a” into the brake caliper recesses “b”.

  • Temporarily tighten the pad pin at this point.

e.Install the brake caliper “5” and the rear wheel “6”.

Refer to REAR WHEEL.

f.Tighten the pad pin “7”.

  • Pad pin

    17 N·m (1.7 kgf·m, 13 lb·ft)

g.Install the pad pin plug “8” and the protector “9”.

  • Pad pin plug

    2.5 N·m (0.25 kgf·m, 1.8 lb·ft)

  • Rear brake caliper protector bolt

    7 N·m (0.7 kgf·m, 5.2 lb·ft)

4.Check:

5.Check:

REMOVING THE REAR BRAKE CALIPER

Before disassembling the brake caliper, drain the brake fluid from the entire brake system.

1.Remove:

  • Union bolt

  • Copper washer

  • Brake hose

Put the end of the brake hose into a container and pump out the brake fluid.

DISASSEMBLING THE REAR BRAKE CALIPER

1.Remove:

  • Brake caliper piston “1”

  • Brake caliper piston dust seal “2”

  • Brake caliper piston seal “3”

a.Blow compressed air into the brake hose joint opening to force out the piston from the brake caliper.

  • Cover the brake caliper piston with a rag. Be careful not to get injured when the piston is expelled from the brake caliper.

  • Never try to pry out the brake caliper piston.

b.Remove the brake caliper piston dust seal and the brake caliper piston seal.

CHECKING THE REAR BRAKE CALIPER

1.Check:

  • Brake caliper piston “1”

    Rust/scratches/wear → Replace the brake caliper piston.

  • Brake caliper cylinder “2”

    Scratches/wear → Replace the brake caliper assembly.

  • Brake caliper body “3”

    Cracks/damage → Replace the brake caliper assembly.

  • Brake fluid delivery passages

    (brake caliper body)

    Obstruction → Blow out with compressed air.

When the brake caliper is disassembled, replace the brake caliper piston seal and the brake caliper piston dust seal with new ones.

2.Check:

  • Brake caliper bracket

    Crack/damage → Replace.

ASSEMBLING THE REAR BRAKE CALIPER

  • Before installation, clean and lubricate the internal parts. Use new brake fluid for cleaning and lubricating.

  • Never use solvents on internal brake components as they will cause the piston seals to swell and distort.

  • When the brake caliper is disassembled, replace the brake caliper piston seal and the brake caliper piston dust seal with new ones.

  • Specified brake fluid

    DOT 4

INSTALLING THE REAR BRAKE CALIPER

1.Install:

  • Rear brake caliper

  • Rear brake caliper bracket

2.Install:

  • Copper washer

  • Brake hose

  • Union bolt

  • Brake hose union bolt

    30 N·m (3.0 kgf·m, 22 lb·ft)

Proper brake hose routing is essential to insure safe vehicle operation.

Make sure that a bend in its pipe portion “a” is directed as shown and the brake hose touches the projection “b” on the brake caliper.

3.Install:

  • Brake pad spring

  • Brake pad

  • Brake pad pin

  • Brake pad pin plug

    • Brake pad pin

      17 N·m (1.7 kgf·m, 13 lb·ft)

    • Brake pad pin plug

      2.5 N·m (0.25 kgf·m, 1.8 lb·ft)

    Refer to CHECKING THE REAR BRAKE PADS.

4.Pour brake fluid to the brake fluid reservoir up to the specified level.

  • Specified brake fluid

    DOT 4

  • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.

  • When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.

Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.

5.Bleed:

6.Check:

7.Check:

REMOVING THE REAR BRAKE MASTER CYLINDER

Before removing the rear brake master cylinder, drain the brake fluid from the entire brake system.

1.Remove:

  • Union bolt

  • Copper washer

  • Brake hose

To drain any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.

CHECKING THE REAR BRAKE MASTER CYLINDER

1.Check:

  • Brake master cylinder “1”

    Damage/scratches/wear → Replace.

  • Brake fluid delivery passages “2”

    (brake master cylinder body)

    Obstruction → Blow out with compressed air.

2.Check:

  • Brake master cylinder reservoir cap

    Crack/damage → Replace.

  • Brake master cylinder reservoir diaphragm holder

  • Brake master cylinder reservoir diaphragm

    Crack/damage → Replace.

3.Check:

  • Brake hose

    Cracks/damage/wear → Replace.

ASSEMBLING THE REAR BRAKE MASTER CYLINDER

  • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid.

  • Never use solvents on internal brake components.

  • Specified brake fluid

    DOT 4

1.Wash the brake master cylinder with brake fluid.

2.Install:

  • Primary cylinder cup “1”

  • Secondary cylinder cup “2”

    (to the brake master cylinder piston “3”)

Apply brake fluid to the cylinder cups and install them as shown. Wrong orientation in installation causes poor braking performance.

3.Install:

  • Spring “1”

    (to the brake master cylinder piston “2”)

Install the spring with a smaller inside diameter to the brake master cylinder piston.

4.Install:

  • Brake master cylinder piston assembly “1”

  • Push rod “2”

  • Circlip “3”

  • Dust boot “4”

  • Before installation, apply brake fluid to the brake master cylinder piston assembly.

  • Before installation, apply silicone grease to the push rod end.

  • Before installation, apply brake fluid to the inside of the brake master cylinder.

INSTALLING THE REAR BRAKE MASTER CYLINDER

1.Install:

  • Copper washer

  • Brake hose

  • Union bolt

  • Brake hose union bolt

    30 N·m (3.0 kgf·m, 22 lb·ft)

Proper brake hose routing is essential to insure safe vehicle operation.

Make sure that the pipe portion of the brake hose touches the projection “a” on the brake caliper.

2.Pour brake fluid to the brake fluid reservoir up to the specified level.

  • Specified brake fluid

    DOT 4

  • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.

  • When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.

Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.

3.Bleed:

4.Check:

5.Check: