Rear Brakes
Rear Brake Caliper Disassembly and Reassembly
Rear Brake Components
NOTE:
If the inside surface of the cylinder (bore wall) and outside surface of piston are damaged, brake fluid leaks may result.
Be extremely careful not to damage the inside surface of the cylinder and outside surface of piston when removing the piston seal.
DISASSEMBLY
Caliper cylinder
1) Clean around caliper cylinder.
2) Remove return spring (1).
3) Remove parking nut (2), washer (3), lever (4) and shaft cover (5).
4) Loosen piston (1) by turning in arrow direction using special tool.
Special Tool
(A): 09945-16060
5) Remove cylinder boot, piston seal and bleeder plug.
Slide pin
Remove slide pins (2) and pin boots (3) from caliper rear brake caliper carrier (1).
Reassembly
WARNING:
Failure to take proper precautions when assembling the brake caliper can result in brake system failure, which could lead an accident.
- Clean each part before installation using the same brake fluid as that in the master cylinder reservoir. Never use any other brake fluid or volatile solvent.
- Before installing the piston seal and cylinder boot to the cylinder, apply rubber grease included in the piston seal set or brake fluid to them.
- Fit a new piston seal, securely into the groove of the cylinder making sure that it is not twisted.
NOTE:
If you do not bleed air from the brake system after replacement of a brake pipe or hose, brake system performance may be affected.
Be sure to bleed the brake system referring to Service and Repair Air Bleeding of Brake System
after replacement of a brake pipe or hose.
Caliper
1) Perform the following procedures before installing brake piston to rear brake caliper.
a) Check entire periphery of brake piston and inside face of cylinder for rust, corrosion and any other damage. If any fault is found, replace rear brake caliper.
b) Apply brake fluid to new piston seal (1) and install into groove in cylinder of rear brake caliper without twisting.
Brake fluid
Refer to reservoir cap of brake master cylinder.
c) Apply brake fluid to new cylinder boot (1) and fit into cylinder boot groove of rear brake caliper as shown below.
Brake fluid
Refer to reservoir cap of brake master cylinder.
2) Expand cylinder boot (1) and install piston (2) into caliper cylinder (3).
3) Turn piston (1) in arrow direction using special tool to screw piston into caliper cylinder.
4) Fit cylinder boot into boot groove of piston.
NOTE:
Check that cylinder boot is securely fitted to entire boot groove of cylinder inner face of rear brake caliper and that of piston.
Special Tool
(A): 09945-16060
5) Apply grease to new shaft cover (1) inner surface and install to rear brake caliper.
NOTE:
Use rubber grease of which viscosity varies very little even at -40°C (-40°F).
6) Install lever (2) and washer (3) and tighten parking nut (4) to specified torque.
Tightening torque
Parking nut (a): 27 Nm (2.8 kgf-m, 20.0 lbf-ft)
7) Install return spring (5) and engage it with lever.
8) Install bleeder plug to rear brake caliper and tighten to specified torque.
Tightening torque
Bleeder plug (a): 7.0 Nm (0.71 kgf-m, 5.5 lbf-ft)
Slide pin
9) Check the following points before installing slide pin to rear brake caliper carrier.
a) Check slide pins for rust, corrosion and other damage and replace them if defective.
b) Apply grease to inner side of new pin boot (1).
c) Direct pin boots (1) as shown and install them to rear brake caliper carrier (2).
NOTE:
Use rubber grease of which viscosity varies very little even at -40°C (-40°F).
d) Apply grease to slide pin (1).
NOTE:
Use rubber grease of which viscosity varies very little even at -40°C (-40°F).
10) Install slide pin with three grooves (upper side) (1) and slide pin without groove (lower side) (2) to rear brake caliper carrier (3) as shown.
