REAR BRAKE INSTALLATION

PROCEDURE


  1. INSTALL REAR DISC


    1. A00580ME01
      Text in Illustration
      *1 Matchmark

      Align the matchmarks of the disc and axle hub and install the disc.

      Note

      When replacing the disc with a new one, select the installation position where the rear disc has minimal runout.

  2. INSTALL REAR DISC BRAKE CYLINDER MOUNTING


    1. A0058H3

      Install the rear disc brake cylinder mounting to the axle carrier with the 2 bolts.

      Torque:
      101 N*m  { 1030 kgf*cm, 74 ft.*lbf }

  3. INSTALL REAR DISC BRAKE BUSH DUST BOOT


    1. A0052F4E02
      Text in Illustration
      *1 Lithium soap base glycol grease

      Apply a light coat of lithium soap base glycol grease to the entire circumference of 2 new rear disc brake bush dust boots where they contact the rear disc brake cylinder mounting, and the entire inner circumference of both ends of the boots.

      Tech Tips

      Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol grease to the rear disc brake bush dust boot.

      Note

      Apply a sufficient amount of lithium soap base glycol grease to the entire circumference of the rear disc brake bush dust boot and rear disc brake cylinder mounting contact surfaces.

    2. Install the 2 rear disc brake bush dust boots to the rear disc brake cylinder mounting.

  4. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH


    1. A0053OHE02
      Text in Illustration
      *1 Lithium soap base glycol grease

      Apply lithium soap base glycol grease to the rear disc brake cylinder slide pin, as shown in the illustration.

    2. Install a new rear disc brake cylinder slide bush to the rear disc brake cylinder slide pin.

  5. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN


    1. A00573XE02
      A0053D1

      Apply lithium soap base glycol grease to the sliding part and the seal surface of the 2 rear disc brake cylinder slide pins.

      Text in Illustration
      *1 Lithium soap base glycol grease

      Install the 2 rear disc brake cylinder slide pins to the rear disc brake cylinder mounting.

  6. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE


    1. A0052PK

      Install the 4 rear disc brake pad support plates to the rear disc brake cylinder mounting.

      Note

      Be sure to install each rear disc brake pad support plate in the correct position and direction.

  7. INSTALL REAR DISC BRAKE PAD


    1. A0057O3

      Install the 2 rear disc brake pads to the rear disc brake cylinder mounting.

      Note

      Make sure there is no oil or grease on the friction surfaces of the disc brake pads or the rear disc.

  8. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY


    1. A0057W8E02
      Text in Illustration
      *a Identification Mark

      To compensate for pad lining thickness, use SST to adjust the protrusion of the rear disc brake piston using the procedure below:


      1. Set SST to the rear disc brake cylinder assembly as shown in the illustration.

        SST
        09719-12010   ( 09719-01010, 09719-01020, 09719-01030 )
        09719-12020

        Tech Tips

        Using the following table, select SST in accordance with the rear disc brake cylinder assembly that is being installed.

        SST Identification Mark
        for LH Side

        09719-12020

        (Left-hand Threads)

        		 L
        for RH Side

        09719-01010

        (Right-hand Threads)

        		 R

      2. Turn SST (A) to secure it to the rear disc brake cylinder assembly.

      3. A0056GBE02
        Text in Illustration
        *a 90°

        Turn SST to adjust the protrusion of the rear disc brake piston.

        Note


        • Place the rear disc between the 2 rear disc brake pads and determine the piston return value.

        • Turn the rear disc brake piston to the position where the protrusion on the pad lines up properly with the piston groove.

    2. A0052IC

      Hold the rear disc brake cylinder slide pin, and install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with the 2 new bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  9. CONNECT REAR BRAKE FLEXIBLE HOSE


    1. A0056YK

      Install a new gasket and connect the flexible hose to the rear disc brake cylinder assembly with a new union bolt.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

      Tech Tips

      Install the flexible hose lock securely into the lock hole in the disc brake cylinder.

  10. ADJUST BUILT-IN CLEARANCE


    1. Secure the rear disc with one of the wheel nuts.

      Torque:
      Maximum tightening torque
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Make sure the rear disc is restrained.

    3. Start the engine.

    4. Depress brake pedal slowly (around 3 seconds) for 5 times.*1

    5. A0059APE03
      Text in Illustration
      *a 0.4 mm

      Using a thickness gauge, check the clearance between the outer pad and disc is less than 0.4 mm (0.0158 in.) when caliper is pushed fully outward.*2

    6. If necessary repeat *1 and *2 steps.

    7. Stop the engine.

    8. Remove the wheel nut temporarily secured on the disc.

  11. CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY


    1. A0055B7E01
      Text in Illustration
      *1 Claw

      Attach the claw of the No. 3 parking brake cable assembly to the rear disc brake cylinder assembly, as shown in the illustration.

    2. Connect the No. 3 parking brake cable assembly with the pin and a new clip to the rear disc brake cylinder assembly.

      A0057CF

      Note


      • The pin and clip must be installed as shown in the illustration.

      • Make sure that the cable boot is not damaged and that the cable is securely connected.

      • If the boot is twisted, it can be adjusted by hand by up to 45° in either direction.

    3. Attach the clamp to the trailing arm.

    4. A0057M0

      Install the bolt.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  12. INSTALL PARKING BRAKE LEVER PROTECTOR

  13. REMOVE CENTER COWL TOP VENTILATOR LOUVER

    Click here

  14. FILL RESERVOIR WITH BRAKE FLUID

    Click here

  15. BLEED BRAKE LINE

    Click here

  16. BLEED CLUTCH LINE (for EC60)

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  17. INSPECT FOR BRAKE FLUID LEAK

  18. INSTALL CENTER COWL TOP VENTILATOR LOUVER

    Click here

  19. INSPECT BRAKE FLUID LEVEL

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  20. CANCEL PARKING BRAKE FULL RELEASE MODE

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  21. INSTALL REAR WHEEL

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }