Replacement of brake pads
1. Remove the rear wheel and temporarily secure the brake disc with wheel nuts.
2. Through the control hole in the caliper, check the thickness of the brake pads.
- Minimum thickness - 1.0 mm
Replace pads if necessary.
3. Raise the caliper.
A) Turn away a bolt of fastening.
b) Raise the caliper and secure it.
Note: Do not disconnect the brake hose from the caliper.
4. Remove the following parts:
- two brake pads
- two anti-squeal pads.
- two retaining plate inserts.
5. Check disc thickness and runout (see "Checking and repairing the rear brakes").
6. Install two retaining plate bushings.
7. Install new pads.
Note: Do not install old anti-squeak pads.
A) Install anti-squeal pads on the brake pads.
b) Install the inner brake pads.
Caution: Do not allow oil or grease to come into contact with the running surfaces of the pads and disc.
8. Install the caliper.
A) Remove a small amount of brake fluid from the reservoir.
b) Push the piston into the cylinder with a piece of wood.
Note: If the piston does not move well, loosen the bleeder screw and retract the piston if there is a slight leakage of brake fluid.
V) Install the support.
G) While holding the guide pin, tighten the bolt.
- Tightening torque - 20 Nm
9. Install the rear wheel.
- Tightening torque - 105 Nm
10. Check fluid level in reservoir and top up if necessary.
11. Press the brake pedal several times to install the pads.
Removing the caliper
1. Disconnect the brake hose.
A) Turn away a union bolt remove two linings and disconnect a brake hose.
b) Drain the brake fluid into a suitable container.
2. Remove the caliper.
A) Turn away a bolt of fastening.
b) Remove the caliper from the bracket.
Rear disc brakes.
1 - gasket,
2 - support,
3 - caliper bracket,
4 - plug,
5 - cap,
6 - brake disc,
7 - dust cover,
8 - cuff,
9 - piston,
10 - cover,
11 - spring ring,
12 - dust cover,
13 - retaining plate insert,
14 - external brake shoe,
15 - anti-creak gasket,
16 - inner brake shoe,
17 - guide pin,
18 - brake disc.
3. Remove the brake pads.
4. Turn away bolts of fastening and remove a support bracket.
Caliper disassembly
1. Using a screwdriver, remove the brake cylinder boot spring ring and boot.
2. Remove the piston.
A) Place a rag between piston and cylinder.
b) Using compressed air, remove the piston from the cylinder.
Caution: Do not place your fingers in front of the piston when using compressed air.
3. Using a screwdriver, remove the piston collar.
Checking and repairing the rear brakes
1. Using a ruler, measure the thickness of the brake pads.
- Standard thickness - 10.0 mm
- Minimum thickness - 1.0 mm
If the thickness of the brake pads is less than the minimum or uneven wear of the pads is found, then replace the brake pads.
2. Using a vernier caliper, measure the thickness of the brake disc.
- Standard thickness - 9.0 mm
- Minimum thickness - 8.0 mm
If the disc thickness is less than the minimum allowable, then replace the disc.
3. Measure the runout of the brake disc at a distance of 10 mm from the outer edge.
- Maximum runout - 0.15 mm
Note: Before measuring brake disc runout, make sure the rear wheel bearing end play is within specification.
4. Replace the brake disc if necessary.
A) Remove the caliper bracket.
b) Loosen the wheel nuts and remove the disc.
V) Install a new brake disc and temporarily secure it with wheel nuts.
G) Install the caliper bracket and tighten the mounting bolts.
- Tightening torque - 47 Nm
Caliper Assembly
1. Apply grease to the surfaces indicated by the arrows in the assembly drawing.
2. Install the piston collar and piston into the cylinder.
3. Install boot and circlip.
4. Install the bleed screw.
- Tightening torque - 8.5 Nm
Caliper installation
1. Install the brake pads.
Caution: Do not allow oil or grease to come into contact with the running surfaces of the pads and disc.
2. Install the caliper and tighten the mounting bolt.
- Tightening torque - 20 Nm
3. Connect the brake hose.
Install the brake hose with two new gaskets.
- Tightening torque - 30 Nm
4. Fill the reservoir with brake fluid and bleed the brake system.
5. Check for leaks.