Rear

DISASSEMBLY








1. Remove piston by turning it counterclockwise with suitable long nose pliers or commercial service tool.





2. Remove snap ring from piston with suitable pliers and remove adjusting nut.
3. Disassemble cylinder body.





a. Pry off snap ring with suitable pliers, then remove spring cover, spring and seat.
b. Remove snap ring, then remove key plate, push rod and strut.





c. Remove piston seal.
Be careful not to damage cylinder body.

Return Spring, Toggle Lever And Cable Guide Removal:

4. Remove return spring, toggle lever and cable guide.

INSPECTION

CAUTION: Use brake fluid to clean cylinder. Never use mineral oil.

Cylinder Body
Check inside surface of cylinder for scoring, rust, wear, damage or presence of foreign objects. If any of the above conditions are observed, replace cylinder body. Minor damage from rust or foreign objects may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.

Torque Member
Check for wear, cracks or other damage. Replace if necessary.

Piston

CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign objects are stuck to sliding surface.

Check piston for score, rust, wear, damage or presence of foreign objects. Replace if any of the above conditions are observed.

Slide Pin, Pin Bolt, And Pin Boot
Check for wear, cracks or other damage. Replace if any of the above conditions are observed.

Rotor
Rubbing Surface
Check rotor for roughness, cracks or chips.

Runout
1. Secure rotor to wheel hub with at least two nuts (M12 x 1.25).

Checking Rotor Runout:

2. Check runout using a dial indicator.
Make sure that wheel bearing axial end play is within the specifications before measuring.
3. Change relative positions of rotor and wheel hub so that runout is minimized.
Maximum runout: 0.07 mm (0.0028 inch)

Thickness





Rotor repair limit:
Minimum thickness 6.0 mm (0.236 inch)
Thickness variation (At least 8 positions)
Maximum 0.02 mm (0.0008 inch)
Replace rotor if any of the above do not meet the specifications.

ASSEMBLY





1. Insert cam with depression facing towards open end of cylinder.





2. Generously apply rubber grease to strut and push rod to make insertion easy.





3. Match protrusion on key plate with depression in cylinder.





4. Install snap ring with a suitable tool.





5. Install seat, spring, spring cover and snap ring while depressing with a suitable tool.





6. Install adjuster in the specified direction.

Piston Component Installation:

7. Install cup, adjuster, bearing, spacers, washer and snap ring with a suitable tool.
8. Insert piston seal into groove on cylinder body.








9. With piston boot fitted to piston, insert piston boot into groove on cylinder body and fit piston by turning it clockwise with long nose pliers, or suitable tool.





10. Adjust the piston to the right angle as shown in the figure.





11. Fit toggle lever, return spring and cable guide.