OVERHAUL. Remove the union bolt and a gasket from the disc brake cylinder, then disconnect the flexible hose from the disc brake cylinder.

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1 OVERHAUL COMPONENTS: See page 3232 Overhaul the RH side by the same procedures with LH side. Two types of brake pad exist; one is with slit and the other without slit. 1. REMOVE REAR WHEEL 2. DRAIN FLUID Wash the brake fluid off immediately if it comes into contact with any painted surfaces. 3. DISCONNECT REAR LH FLEXIBLE HOSE E801 Remove the union bolt and a gasket from the disc brake cylinder, then disconnect the flexible hose from the disc brake cylinder. 4. REMOVE REAR DISC CYLINDER SLIDE PIN Remove the rear disc brake cylinder slide pin. F REMOVE DISC CYLINDER ASSY REAR LH Lift up the disc brake cylinder and remove the disc brake cylinder. F REMOVE REAR DISC CYLINDER SLIDE BUSH Remove the cylinder slide bush from the disc brake cylinder. F

2 REMOVE REAR DISC BUSH DUST BOOT Remove the bush dust boot from the cylinder slide pin. F REMOVE REAR DISC CYLINDER SLIDE PIN Using a hexagon wrench (8 mm), remove the cylinder slide pin. F REMOVE DISC PAD KIT REAR (PAD ONLY) Remove the 2 brake pads with anti squeal shims. 10. REMOVE REAR DISC ANTI SQUEAL SHIM KIT Remove the 2 anti squeal shims from 2 brake pads. (b) Using a screwdriver, remove the wear indicator from 2 brake pads. F REMOVE REAR DISC PAD SUPPORT PLATE Remove the upper side rear disc brake pad support plate. 12. REMOVE REAR DISC PAD SUPPORT PLATE Remove the bottom side rear disc brake pad support plate. 13. REMOVE REAR DISC CYLINDER MOUNTING LH Remove the 2 bolts and disc brake cylinder mounting. F

3 REMOVE CYLINDER BOOT Using a screwdriver, remove the set ring and cylinder boot from the disc brake cylinder. F REMOVE REAR DISC DISC PISTON Place a piece of cloth or like, between the piston and the disc brake cylinder. (b) Use compressed air to remove the piston from the disc brake cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed air. C82872 Do not spatter the brake fluid. 16. REMOVE PISTON SEAL Using a screwdriver, remove the piston seal from the disc brake cylinder. Do not damage the inner cylinder and the cylinder groove. 17. REMOVE REAR DISC BLEEDER PLUG CAP 18. REMOVE REAR DISC BLEEDER PLUG 19. INSPECT CYLINDER AND PISTON Check the cylinder bore and piston for rust or scoring. 20. INSPECT PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. USA, Canada models: Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 1.0 mm (0.039 in.) Brazil models: Standard thickness: 11.0 mm (0.433 in.) Minimum thickness: 1.0 mm (0.039 in.) F INSPECT REAR DISC PAD SUPPORT PLATE Make sure that they have sufficient rebound, no deformation cracks or wear, and all rust, dirt are cleaned off. 22. INSPECT REAR DISC PAD SUPPORT PLATE Make sure that they have sufficient rebound, no deformation cracks or wear, and all rust, dirt are cleaned off. 1792

4 INSPECT DISC THICKNESS Using a micrometer, measure the disc thickness. USA, Canada models: Standard thickness: 12.0 mm (0.472 in.) Minimum thickness: 10.5 mm (0.413 in.) Brazil models: Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 8.5 mm (0.335 in.) F REMOVE PARKING SHOE ADJUSTING HOLE PLUG Matchmark 25. REMOVE REAR DISC Put matchmark on the disc and the axle hub. (b) Remove the disc. 26. INSTALL REAR DISC Aligning the matchmark, install the rear disc. F41555 When replacing the disc with a new one, select the installation position where the disc has the minimum runout. 27. INSTALL PARKING SHOE ADJUSTING HOLE PLUG 28. INSPECT DISC RUNOUT Temporarily install the disc with hub nuts. Torque: 103 N m (1,050 kgf cm, 76 ft lbf) (b) Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the disc. Maximum disc runout: 0.15 mm ( in.) (c) If the disc runout is greater than the maximum value, check the bearing play in the axial direction and check the F41556 axle hub runout (See page 302). If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on a Oncar brake lathe. 29. ADJUST PARKING SHOE CLEARANCE (See page 3318) 30. TEMPORARY TIGHTEN REAR DISC BLEEDER PLUG Temporarily tighten the bleeder plug to the disc brake cylinder. 31. INSTALL REAR DISC BLEEDER PLUG CAP 32. INSTALL PISTON SEAL Apply the lithium soap base glycol grease to a new piston seal. (b) Install the piston seal to the disc brake cylinder. 1793

5 INSTALL REAR DISC DISC PISTON Apply the lithium soap base glycol grease to the piston. (b) Install the piston to the disc brake cylinder. Do not screw the piston forcibly into the disc brake cylinder. 34. INSTALL CYLINDER BOOT Apply the lithium soap base glycol grease to a new cylinder boot. (b) Install the cylinder boot to the disc brake cylinder. Install the boot securely to the grooves of the cylinder and piston. (c) Using a screwdriver, install a new set ring. F41559 Do not damage the cylinder boot. 35. INSTALL REAR DISC CYLINDER MOUNTING LH Install the disc brake cylinder mounting with the 2 bolts. Torque: 61.8 N m (630 kgf cm, 46 ft lbf) 36. INSTALL REAR DISC PAD SUPPORT PLATE Install the bottom side rear disc brake pad support plate. 37. INSTALL REAR DISC PAD SUPPORT PLATE Install the upper side rear disc brake pad support plate. 38. INSTALL REAR DISC ANTI SQUEAL SHIM KIT Shim No.1 Wear Indicator Shim No.2 Shim No.1 Shim No.2 F INSTALL DISC PAD KIT REAR (PAD ONLY) Apply the both sides of anti squeal shim No.1 with pad grease, and install the shim together with anti squeal shim No.2 to each pad. (b) Install the wear indicator to the 2 brake pads. When replacing worn pads, the anti squeal shims must be replaced together with the pads. Install the shims and pad wear indicator correctly of which positions and directions. Install the 2 disc brake pads with the pad wear indicator facing downward. There should be no oil or grease on the friction surface of the pads and the disc. 1794

6 INSTALL REAR DISC CYLINDER SLIDE PIN Using a hexagon wrench (8 mm), install the cylinder slide pin. Torque: 39.2 N m (400 kgf cm, 29 ft lbf) F41551 Cylinder Slide Pin 41. INSTALL REAR DISC BUSH DUST BOOT Apply the lithium soap base glycol grease to seal surface of a new bush dust boot. (b) Install the bush dust boot to the cylinder slide pin. Cylinder Mounting Lithium soap base glycol grease F INSTALL REAR DISC CYLINDER SLIDE BUSH (b) Apply the lithium soap base glycol grease to a new cylinder slide bush. Install the cylinder slide bush to the disc brake cylinder. Lithium soap base glycol grease F INSTALL DISC CYLINDER ASSY REAR LH Apply the lithium soap base glycol grease to the cylinder slide pin. (b) Install the disc brake cylinder to the cylinder slide pin. 44. INSTALL REAR DISC CYLINDER SLIDE PIN Apply the lithium soap base glycol grease to the cylinder slide pin. (b) Install the cylinder slide pin to the disc brake cylinder. Torque: 34.3 N m (350 kgf cm, 25 ft lbf) 45. CONNECT REAR LH FLEXIBLE HOSE Connect a new gasket and flexible hose with the union bolt. Torque: 29.4 N m (300 kgf cm, 22 ft lbf) Install the flexible hose lock securely in the lock hole of the disc brake cylinder. 46. FILL RESERVOIR WITH FLUID 47. BLEED MASTER CYLINDER (See page 324) SST BLEED LINE (See page 324) 49. CHECK FLUID LEVEL IN RESERVOIR 1795

7 CHECK FLUID LEAKAGE 51. INSTALL REAR WHEEL Torque: 103 N m (1050 kgf cm, 76 ft lbf) 1796