Brake

Rear brake

Rear brake
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RB-2
Removal (normal type). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RB-5
Removal (brembo type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RB-8
Disassembly (normal type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RB-10
Disassembly (brembo type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RB-11
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RB-12
Assembly (normal type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RB-13
Assembly (brembo type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RB-14
Installation (normal type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RB-15
Installation (brembo type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RB-17
Rear brake flexible hose
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RB-19

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Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RB-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RB-20

RB
 RB–2 Rear brake － Rear brake

Rear brake
Rear brake
Brake

Exploded view

8.0 {82,5.9}
Ventilated disc brake
Rear disc brake bleeder plug

Slide pin

Rear left flexible hose

Rear disc brake
bleeder plug cap

26 {265,19.2}
26 {265,19.2}
x2 Rear disc brake
bushing dust boot

*1
66 {673,48.7}

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*2 Disc brake cylinder
110 {1122,81.1}
ASSY RR LH
x2

Gasket

Rear disc brake cylinder

mounting LH Rear disc brake
bushing dust boot

Bushing

Slide lock pin

Parking brake shoe

adjusting hole plug

Rear disc

N*m {kgf*cm,ft*lbf} : Tightening torque

RB Non-reusable parts
*1: Width across flat 14 mm {0.5512 in}
Rubber grease (NIGLUBE RX-2) or equivalent *2: Width across flat 17 mm {0.6693 in}
BR-10400
 Rear brake － Rear brake
RB–3

Brembo type
Rear left flexible hose

Union bolt
26 {265, 19.2}

Gasket
Cap bleeder
73 {744, 53.8}
Bleeder screw
20 {204,14.8}

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Caliper body

Guide plate

Parking brake shoe adjusting hole plug

Disc rotor

N*m {kgf*cm, ft*lbf} : Tightening torque

Non-reusable part
BR-10156 RB
 RB–4 Rear brake － Rear brake

Normal type

Rear disc brake cylinder

mounting LH

Disc brake cylinder

ASSY RR LH
Pad clip

Piston seal

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Rear disc brake piston

Cylinder boot

Pad clip
Rear disc brake anti-squeal shim kit

Disc brake pad kit RR

Rear disc brake

anti-squeal shim kit

Non-reusable parts

Rubber grease (RENOLIT rubber grease JP) or equivalent

MP grease No.2 or equivalent

RB BR-10641
 Rear brake － Rear brake
RB–5

Brembo type

Caliper body

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Piston seal
Piston boot
Piston disc brake
Piston disc brake
Piston boot
Piston seal

Shim disc brake rear inner

Cross spring
Pad disc brake rear inner

Pad disc brake rear outer

Shim disc brake rear inner

Clip slide pin

Pin disc brake

Non-reusable parts

Rubber grease (RENOLIT rubber grease JP) or equivalent

MP grease No.2 or equivalent

Disc brake grease II or equivalent BR-10402 RB

Removal (normal type)
NOTE:
• The following procedure is for LH side.
• Perform the same procedures for the RH and LH side.
 RB–6 Rear brake － Rear brake

1. Removal of rear tire

2. Draining of brake fluid
CAUTION:
Do not let brake fluid come into contact with the painted surface. If it happens, wash it out immediately.
3. Disconnection of rear left flexible hose
(1) Remove the union bolt and 2 gaskets to disconnect the rear left
flexible hose from the disk brake cylinder ASSY RR LH.

BR-10629
4. Removal of disc brake cylinder ASSY RR LH
(1) Remove 2 bolts and then the disc brake cylinder ASSY RR LH.

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5. Removal of disc brake pad kit RR
(1) Remove the disc brake pad kit RR from the rear disc brake cylin-
der mounting LH.

BR-10631
6. Removal of rear disc brake anti squeal shim kit
(1) Remove the rear disc brake anti-squeal shim kit from the disc
brake pad kit RR.
Captions in illustration
*1 Disc brake pad kit RR
*2 Rear disc brake anti squeal shim kit


   BR-10632

RB
 Rear brake － Rear brake
RB–7

7. Removal of pad clip

(1) Remove the pad clip.

8. Removal of rear disc brake cylinder mounting LH

(1) Remove 2 bolts and then the rear disc brake cylinder mounting LH.

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9. Removal of parking brake shoe adjusting hole plug
Remove the parking brake shoe adjusting hole plug from the rear disc.
10. Removal of rear disc
(1) Put alignment marks on the rear disc and rear axle hub. (This is
not required when replacing the rear disc.)
C Captions in illustration
*a Alignment marks

(2) Release the parking brake and remove the rear disc.
NOTE:
If it is difficult to remove the rear disc, insert a flat head screwdriver
from the rear disc service hole and rotate the adjusting screw to
contract the parking brake shoe.
Captions in illustration
*a Extend
D *b Contract
C

BR-01232

RB
 RB–8 Rear brake － Rear brake

11. Removal of slide pin

(1) Remove the slide pin from the rear disc brake cylinder mounting
LH.

12. Removal of slide lock pin

(1) Remove the slide lock pin from the rear disc brake cylinder mount-
ing LH.

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(2) Remove the bushing from the slide lock pin.

13. Removal of rear disc brake bushing dust boot

(1) Remove 2 rear disc brake bushing dust boots from the rear disc
brake cylinder mounting LH.

Removal (brembo type)

NOTE:
• The following procedure is for LH side.
RB • Perform the same procedures for the RH and LH side.
1. Removal of rear tire
2. Draining of brake fluid
CAUTION:
Do not let brake fluid come into contact with the painted surface. If it happens, wash it out immediately.
 Rear brake － Rear brake
RB–9

3. Removal of pad disc brake rear


(1) Remove the clip slide pin, and remove the pin disc brake and
cross spring.
(2) While pushing back the piston using a wrench, remove the pad
disc brake rear.
Captions in illustration
*1 Clip slide pin
*2 Pin disc brake
*3 Cross spring
*4 Pad disc brake
 

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 BR-10120

4. Disconnection of rear left flexible hose

(1) Remove the union bolt and 2 gaskets, and then remove the rear
left flexible hose from the caliper body ASSY.

BR-10121

5. Removal of disc brake ASSY

(1) Remove the 2 bolts, and remove the caliper body ASSY.

BR-10122

6. Removal of parking brake shoe adjusting hole plug

Remove the parking brake shoe adjusting hole plug from the disc rotor.

RB
 RB–10 Rear brake － Rear brake

7. Removal of disc rotor

(1) Put alignment marks on the disc rotor and rear axle hub. (It is not
necessary when replacing the disc rotor).
C Captions in illustration
*a Alignment marks

(2) Release the parking brake and remove the disc rotor.
NOTE:
If it is difficult to remove the disc rotor, insert a flat head screw-
driver from the disc rotor service hole and rotate the adjusting
screw to contract the parking brake shoe.
Captions in illustration
*a Extend
D *b Contract
C

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BR-01232

Disassembly (normal type)

1. Removal of rear disc brake piston
(1) Put a wooden block between the rear disc brake piston and the
disc brake cylinder to prevent the rear disc brake piston from being
damaged.
Captions in illustration
*1 Wooden block
*a 30mm {1.181in}

(2) Using an air gun, gradually blow air into the applicable part to
remove the rear disc brake piston.
WARNING:
Be careful not to pinch your fingers.
CAUTION:
 Be careful not to spill brake fluid.
C

2. Removal of cylinder boot

(1) Using a thin flat tip screwdriver, remove the cylinder boot from the

disc brake cylinder.
NOTE:
Wrap the tip of the screwdriver with a protective tape.
CAUTION:
Do not damage the cylinder wall and the piston seal groove.
Captions in illustration
RB *1 Protective tape
 Rear brake － Rear brake
RB–11

3. Removal of piston seal

(1) Using a thin flat tip screwdriver, remove the piston seal.

NOTE:
Wrap the tip of the screwdriver with a protective tape.
CAUTION:
Do not damage the cylinder wall and the piston seal groove.
Captions in illustration
*1 Protective tape

4. Removal of cap bleeder

(1) Remove the cap bleeder from the bleeder screw.
5. Removal of bleeder screw
(1) Remove the bleeder screw.

Disassembly (brembo type)

1. Removal of piston boot
(1) Remove the 2 piston boots.

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BR-10123

2. Removal of piston disc brake


(1) Put a wooden block between the piston disc brake and the caliper
body to prevent the piston disc brake from being damaged.
Captions in illustration
*1 Wooden block
*a 20mm{0.79in}

(2) Using an air gun, gradually blow air into the applicable part to
remove the piston disc brake.
WARNING:
D BR-10124 Be careful not to pinch your fingers.
CAUTION:
Be careful not to spill brake fluid.
3. Removal of piston seal

(1) Using a thin flat tip screwdriver, remove the piston seal.
NOTE:
Wrap the tip of the screwdriver with a protective tape.
CAUTION:
Do not damage the cylinder wall and the piston seal groove.
Captions in illustration
*1 Protective tape

RB
BR-10125

4. Removal of cap bleeder

(1) Remove the cap bleeder from the bleeder screw.
 RB–12 Rear brake － Rear brake

5. Removal of bleeder screw

(1) Remove the bleeder screw.

Inspection
1. Disc brake piston and cylinder check
(1) Check that there is no damage on the side of the disc brake piston and on the disc brake cylinder wall.
2. Disc brake pad thickness check
• Normal type
Limit: 1.5mm{0.059in}
Reference value: 11.0 mm {0.433 in} (New)
• Brembo type
Limit: 1.55 mm {0.061 in}
Reference value: 9.0mm{0.354in}

3. Disc thickness check

• Normal type

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Limit: 16.0 mm {0.630 in}
Reference value: 18.0mm {0.709in} (New)
• Brembo type
Limit: 18.0 mm {0.709 in}
Reference value: 20.0mm {0.787in}

BR-01108

4. Disc runout check

(1) Before checking the rear disc runout, check the rear axle hub bearing play (Refer to AD - 22) and runout (Refer to AD -
23).
(2) Secure the rear disc with 5 wheel nuts.
Standard value:T=120N·m {1224kgf·cm} {88.5ft·lbf}

(3) Using a dial gauge, set at 10 mm {0.394 in} inside from the rear
disc outer periphery to check the front side runout.
Captions in illustration
*1 Dial gauge

• Normal type
Limit: 0.05mm{0.002in}
• Brembo type
Limit: 0.07 mm {0.003 in}
CAUTION:
 When the runout exceeds the limit, change the positions of the rear
BR-10026
disc and rear axle hub to minimize the runout before installation. If the
runout still exceeds the limit even after changing the rear disc and the
rear axle hub positions, replace the rear disc with new one.

RB
 Rear brake － Rear brake
RB–13

(4) Set the dial gauge at 10 mm {0.39 in} inside from the disc rotor
outer periphery, and rotate the disc rotor to check the back side
runout.
Captions in illustration
*1 Dial gauge

• Normal type
Limit: 0.05mm{0.002in}
 • Brembo type
Limit: 0.07 mm {0.003 in}
BR-10126 NOTE:
<Example of magnet stand and dial gauge installation>
(5) If the disc rotor runout exceeds service limit, grind the disc rotor.
(6) Check the disc rotor thickness after grinding. (Refer to RB - 12)

Assembly (normal type)

1. Temporary tightening of bleeder screw
(1) Temporarily tighten the bleeder screw to the disc brake cylinder ASSY RR LH.
2. Installation of cap bleeder
(1) Install the cap bleeder to the bleeder screw.

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3. Installation of piston seal
(1) Apply rubber grease to a new piston seal and install it in the disc
brake cylinder groove.
Captions in illustration

Rubber grease (RENOLIT rubber grease JP) or equivalent

RB
 RB–14 Rear brake － Rear brake

4. Installation of cylinder boot

(1) Apply a thin coat of rubber grease to the outer periphery of the disc
 brake piston.
Captions in illustration
*1 Piston
 *2 Cylinder boot

Rubber grease (RENOLIT rubber grease JP) or equivalent

 (2) Apply rubber grease to a new cylinder boot and install it to the bot-
tom of the disc brake piston as shown in the figure.

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5. Installation of rear disc brake piston
(1) Attach the seal portion of the cylinder boot to the disc brake cylin-
der groove.
Captions in illustration
 *1 Cylinder boot
*2 Piston
 *3 Cylinder

CAUTION:
Make sure that the seal portion of the cylinder boot is securely
attached.
 (2) Push in the piston by hand, and attach the seal portion of the boot
to the piston groove.
CAUTION:
Make sure that the seal portion of the cylinder boot is securely
attached.

Assembly (brembo type)

1. Temporary tightening of bleeder screw
(1) Temporarily tighten the bleeder screw to the caliper body.
RB 2. Installation of cap bleeder
(1) Install the cap bleeder to the bleeder screw.
 Rear brake － Rear brake
RB–15

3. Installation of piston seal

(1) Apply rubber grease to a new piston seal and install it in the caliper
body groove.
Captions in illustration

Rubber grease (RENOLIT rubber grease JP) or equivalent

BR-10127

4. Installation of piston disc brake

(1) Apply a thin coat of rubber grease to the outer periphery of the pis-
 ton disc brake.
Captions in illustration
*1 Piston disc brake
 *2 Piston boot

Rubber grease (RENOLIT rubber grease JP) or equivalent

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 (2) Apply rubber grease to a new piston boot and install it to the bot-
tom of the piston disc brake as shown in the figure.
(3) Install the seal portion of piston boot to the caliper body grooves.
CAUTION:
Make sure that the seal portion of the piston boot is securely attached.
(4) Push in the piston by hand, and attach the seal portion of the boot
to the piston groove.
CAUTION:
 Make sure that the seal portion of the piston boot is securely attached.

Installation (normal type)

NOTE:
• The following procedure is for LH side.
• Service the LH side and the RH side using the same procedure.
1. Pushing back of piston disc brake
As necessary, push back the piston disc brake using the disc brake piston tool.
CAUTION:
When the piston disc brake is pushed back, the clearance between pad disc brake and brake disc becomes large and the brake
pedal pressure becomes soft.
After installation of the rear tires, be sure to press the brake pedal several times to adjust the clearance and pedal pressure.
2. Installation of rear disc brake bushing duct boot
(1) Apply rubber grease inside a new rear disc brake bushing dust
boot.
Captions in illustration

Rubber grease (NIGLUBE RX-2) or equivalent

RB
NOTE:
Apply at least 1.5±0.2g {0.05±0.007} of rubber grease per 1 rear
disc brake bushing dust boot.
 RB–16 Rear brake － Rear brake

(2) Install 2 rear disc brake bushing dust boots to the rear disc brake
cylinder mounting LH.
3. Installation of slide lock pin
(1) Apply rubber grease to the contacting surface of the new bushing
and the slide lock pin.
Captions in illustration
*1 Slide lock pin
*2 Bushing


Rubber grease (NIGLUBE RX-2) or equivalent


(2) Install the bushing to the slide lock pin.
(3) Apply rubber grease to the sliding part and the engaging part of the
slide lock pin.
(4) Install the slide lock pin to the rear disc brake cylinder mounting
LH.
4. Installation of slide pin
(1) Apply rubber grease to the engaging part and the sliding part of the
slide pin.

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Captions in illustration

Rubber grease (NIGLUBE RX-2) or equivalent

(2) Install the slide pin to the rear disc brake cylinder mounting LH.

5. Installation of rear disc

(1) Aligning the mark which you put at the time of removal, install the rear disc to the axle hub.
NOTE:
When replacing the rear disc with new one, select the position where the rear disc runout becomes the minimum and
install it.
6. Clearance adjustment of disc and lining (Refer to PB - 24)
7. Installation of parking brake shoe adjusting hole plug
(1) Install the parking brake shoe adjusting hole plug to the rear disc.
8. Installation of rear disc brake cylinder mounting LH
NOTE:
Before installation, remove the pad clip and remove mud, foreign matter, and rust from disc brake cylinder ASSY RR LH and
rear disc brake cylinder mounting LH.
(1) Install the rear disc brake cylinder mounting LH with 2 new bolts.
Standard value:Width across flat 14 mm {0.5512 in}
T=66N·m {673kgf·cm} {48.7ft·lbf}
Width across flat 17 mm {0.6693 in}
T=110N·m {1122kgf·cm} {81.1 ft·lbf}

RB
 Rear brake － Rear brake
RB–17

(2) Apply a thin coat of MP grease No.2 or equivalent to the contacting

part of the rear disc brake cylinder mounting LH and the pad clip.
Captions in illustration

MP grease No.2 or equivalent

9. Installation of pad clip

(1) Apply a thin coat of MP grease No.2 or equivalent to the part
where the disc brake pad kit RR of the pad clip contacts.
Captions in illustration

MP grease No.2 or equivalent

(2) Install the pad clip to the rear disc brake cylinder mounting LH.

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10. Installation of rear disc brake anti-squeal shim kit
(1) Install the rear disc brake anti-squeal shim kit to the disc brake pad
kit RR.
Captions in illustration
*1 Disc brake pad kit RR
*2 Rear disc brake anti-squeal shim kit


  
BR-10642

11. Installation of disc brake pad kit RR

(1) Install the disc brake pad kit RR to the rear disc brake cylinder mounting LH.
12. Installation of disc brake cylinder ASSY RR LH
(1) Install the disc brake cylinder ASSY RR LH to the rear disc brake cylinder mounting LH with 2 bolts.
Standard value:T=26N·m {265kgf·cm} {19.2ft·lbf}
13. Connection of rear left flexible hose
(1) Using a new union bolt, connect the rear left flexible hose via 2 new gaskets.
Standard value:T=26N·m {265kgf·cm} {19.2ft·lbf}
14. Brake fluid refill (Refer to BR - 8)
15. Air bleeding of brake system (Refer to BR - 8)
16. Brake fluid leak check
17. Brake fluid level check (Refer to BR - 12)
18. Installation of rear tire
Standard value:T=120N·m {1224kgf·cm} {88.5ft·lbf}

Installation (brembo type)

RB
NOTE:
• The following procedure is for LH side.
• Service the LH side and the RH side using the same procedure.
1. Pushing back of piston disc brake
As necessary, push back the piston disc brake using the disc brake piston tool.
 RB–18 Rear brake － Rear brake

CAUTION:
When the piston disc brake is pushed back, the clearance between pad disc brake and brake disc becomes large and the brake
pedal pressure becomes soft.
After installation of the rear tires, be sure to press the brake pedal several times to adjust the clearance and pedal pressure.
2. Installation of disc rotor
(1) Aligning the mark which you put at the time of removal, install the disc rotor to the axle hub.
NOTE:
When replacing the disc rotor with a new one, select the position where the disc rotor runout becomes the minimum and
install it.
3. Clearance adjustment of disc and lining (Refer to PB - 24)
4. Installation of parking brake shoe adjusting hole plug
(1) Install the parking brake shoe adjusting hole plug to the disc rotor.
5. Installation of caliper body ASSY
(1) Install the caliper body ASSY with 2 bolts.
Standard value:T=73N·m {744kgf·cm} {53.8ft·lbf}

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BR-10122

6. Installation of pad disc brake rear

(1) Apply a thin coat of grease to the side surface of pad disc brake
rear and shim installation surface of pad disc brake rear.
Captions in illustration

Disc brake grease II or equivalent

MP grease No.2 or equivalent

(2) Install the pad disc brake rear.

NOTE:
Install so that the arrow faces upward.
(3) Install the cross spring, pin disc brake and clip slide pin.

BR-10158

7. Connection of rear left flexible hose

(1) Using a new union bolt, connect the rear left flexible hose via 2 new gaskets.
Standard value:T=26N·m {265kgf·cm} {19.2ft·lbf}

RB 8.
9.
Brake fluid refill (Refer to BR - 8)
Air bleeding of brake system (Refer to BR - 8)
10. Brake fluid leak check
11. Brake fluid level check (Refer to BR - 12)
12. Installation of rear tire
Standard value:T=120N·m {1224kgf·cm} {88.5ft·lbf}
 Rear brake － Rear brake flexible hose
RB–19

Rear brake flexible hose

Rear brake
Brake

Exploded view

Ventilated disc brake

26 {265,19.2}

Rear left flexible hose

15 {155,11.1}

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33 {337,24.3}

Gasket

N*m (kgf*cm, ft*lbf) : Tightening torque

Non-reusable parts
BR-10025

Removal
NOTE:
RB
• The following procedure is for LH side.
• Service the LH side and the RH side using the same procedure.
• The procedures described below are for the normal type. For the brembo type, perform the same procedures as the normal
type.
1. Removal of rear tire
 RB–20 Rear brake － Rear brake flexible hose

2. Draining of brake fluid (Refer to RB - 6)

3. Removal of rear left flexible hose
(1) Remove the union bolt and 2 gaskets to disconnect the rear left
flexible hose from the disk brake cylinder ASSY RR LH.

BR-10629

(2) Remove the bolt and disconnect the rear left flexible hose from the
rear carrier LH.

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(3) Secure the rear left flexible hose with a spanner, and disconnect
the brake tube using a flare-nut wrench.
CAUTION:
• Do not bend or damage the brake tubes.
• Do not let foreign matter including dirt and dust enter the connec-
tion part of the brake tube.
(4) Remove the clip.
(5) Remove the rear left flexible hose.

Installation
NOTE:
• The following procedure is for LH side.
• Perform the same procedures for the RH and LH side.
• The procedures described below are for the normal type. For the brembo type, perform the same procedures as the normal
type.
1. Installation of rear left flexible hose
(1) With a new clip, install the rear left flexible hose.
CAUTION:
Securely attach the clip as far as it will go.
(2) Secure the rear left flexible hose with a spanner, and connect the brake tube to the rear left flexible hose using a flare-nut
wrench.
Standard value:T=15N·m {155kgf·cm} {11.1ft·lbf}
RB CAUTION:
• Do not bend or damage the brake tubes.
• Do not let foreign matter including dirt and dust enter the connection part of the brake tube.
(3) With a bolt, connect the rear left flexible hose to the rear carrier LH.
Standard value:T=33N·m {337kgf·cm} {17.7ft·lbf}
(4) Using a new union bolt, install the rear left flexible hose to the disc brake cylinder ASSY RR LH via two new gaskets.
 Rear brake － Rear brake flexible hose
RB–21

Standard value:T=26N·m {265kgf·cm} {19.2ft·lbf}

2. Brake fluid refill (Refer to BR - 8)
3. Air bleeding of brake system (Refer to BR - 8)
4. Brake fluid leak check
5. Brake fluid level check (Refer to BR - 12)
6. Installation of rear tire
Standard value:T=120N·m {1224kgf·cm} {88.5ft·lbf}

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RB
 RB–22 Rear brake － Rear brake flexible hose

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RB