REAR BRAKE CALIPER
REMOVAL
Drain the rear brake hydraulic system (page 16-6). Remove the brake pads (page 16-10).
Remove the bolts and brake caliper guard.
Loosen the oil bolt.
Remove the rear wheel (page 15-8).
|
BRAKE CALIPER/BRACKET ASSEMBLY
|
Slide the brake caliper and bracket assembly backward and pull it off of the slide rail on the swingarm.
Remove the brake hose oil bolt, sealing washers and brake hose eyelet.
Remove the bolts and brake disc cover.
|
|
|
|
Remove the caliper bracket from the caliper body.
Remove the brake pad spring from the caliper body. Remove the brake pad retainer from the caliper bracket.
Remove the caliper pin boot and bracket pin boot.
If necessary, lightly apply compressed air to the caliper fluid inlet to get piston out.
|
|
Place a shop rag under the caliper to cushion the piston when it is expelled.
|
Do not bring the air nozzle too close to the inlet or the pistons may be forced out with excessive force that could cause injury. |
Use the air in short spurts.
|
Be careful not to damage the piston sliding surface. |
|
PISTON |
|
|
|
SEAL |
|
DUST INSPECTION Check the caliper cylinder and piston for scoring, Measure the caliper cylinder I. D. SERVICE LIMIT: 22.712 mm (0.8942 in) |
|
Push the dust seal and piston seal in and lift them out. Clean the seal grooves, caliper piston and caliper piston sliding surface with clean brake fluid. |
Measure the caliper piston O. D. SERVICE LIMIT: 22.573 mm (0.8887 in)
|
|
Coat new piston seal with clean brake fluid.
|
DUST SEAL |
|
PISTON SEAL |
|
CALIPER PISTON |
|
|
Coat new dust seal with silicone grease.
|
Install the piston seal, dust seal and caliper piston in their proper locations. |
Install the piston and dust seals into the grooves in the caliper body.
Coat the caliper piston with clean brake fluid and install it into the caliper cylinder with its open end facing the pad.
|
BOOTS |
|
PAD SPRING |
|
CALIPER |
|
CALIPER BRACKET |
|
RETAINER |
|
|
Install the brake pad retainer onto the caliper bracket.
Install the pad spring into the caliper body.
Replace the caliper and bracket pin boots if there is wear, deterioration or damage.
Apply silicone grease to the inside of the boots then install them.
Apply silicone grease to the caliper pin bolt sliding area.
|
When assembling the caliper and bracket, set the boot into the slide pin groove. |
Assemble the caliper and bracket.
|
BOLTS |
|
|
Install the brake disc cover and tighten the bolts securely.
|
|
DISC COVER
|
|
Install the brake hose eyelets to the caliper body with new sealing washers and oil bolt.
Install the brake caliper/bracket assembly onto the swingarm by aligning the bracket tab with the slide rail on the swingarm.
|
BRAKE CALIPER/BRACKET ASSEMBLY |
Install the rear wheel (page 15-13).
Install the brake pad (page 16-10).
SLIDE RAIL
|
OIL BOLT |
|
CALIPER GUARD |
Push the brake hose eyelet to the stopper on the caliper, then tighten the oil bolt to the specified torque.
TORQUE: 34 N m (3.5 kgf m, 25 lbf-ft)
Install the caliper guard and tighten the bolts securely.
Fill and bleed the rear brake hydraulic system (page
16-7).
BOLTS
