Note: The assembled parts should look like the picture.
With automatic gap adjuster.
Without automatic gap adjuster.
With small diameter brake drums.
Rear brake (DYNA 150).
1, 19 - Retainer,
2 - Holder,
3 Brake shield,
4 - Upper and lower brake pads,
5 - Cap,
6 - Retaining spring,
7 - Brake drum,
8 - Return spring,
9 - Wheel cylinder,
10 - Spring seat,
11 - Spring,
12 - Dust cover,
13 - Adjusting bolt,
14 - Adjusting nut,
15 - Dust seal,
16 - Saddle,
17 - Wheel cylinder piston assembly,
18 - Automatic regulator lever,
20 - Bleed nipple,
21 - Piston,
22 - Regulator locking lever.
Rear brake (DYNA 150).
1 - Bracket,
2 - Brake pipe,
3 - Holder,
4 - Cap,
5 - Retaining spring,
6 - Bleed nipple,
7 - Return spring,
8 - Brake drum,
9 - Brake pads,
10 - Brake shield,
11 - Adjusting bolt,
12 - Adjusting nut,
13 - Dust cover,
14 - Spring seat,
15 - Spring,
16 - Piston,
17 - Wheel cylinder,
18 - Regulator locking lever.
1. Assemble the wheel cylinder. (With automatic gap adjuster)
a) Apply lithium based grease as shown in the figure.
b) Apply high temperature grease to the adjusting bolt.
c) Assemble the wheel cylinder in the following sequence: return spring, two spring seats, two caps, piston, two dust boots, wheel cylinder piston assembly and automatic adjuster lever with spring, lock, screw.
d) Install the seat and dust seal onto the wheel cylinder piston assembly.
d) Install the adjusting nut and bolt onto the wheel cylinder piston assembly.
- Right wheel cylinder (marked R): Right-hand thread (Yellow)
- Left wheel cylinder (marked L): Left-hand thread (White)
(Without automatic gap adjuster)
a) Apply lithium based grease as shown in the figure.
b) Apply high temperature grease to the adjusting bolt.
c) Assemble the wheel cylinder in the following sequence: return spring, two spring seats, two caps, piston, two dust boots.
d) Install the adjusting nut and bolt onto the wheel cylinder.
- Right wheel cylinder (marked R): Left-hand thread (Yellow)
- Left wheel cylinder (marked L): Right-hand thread (White)
d) Install the regulator locking lever and tighten the screw.
2. Install the bleed nipple as shown in the figure.
a) The wheel cylinder nipple sockets on the front side are made flat and conical in shape, as shown in the figure.
b) Both nipple sockets on the rear side of the wheel cylinder are made conical.
3. Install the wheel cylinder onto the brake shield.
a) (With automatic gap adjuster) Install the front wheel cylinder with the adjusting mechanism down and the rear wheel cylinder with the adjusting mechanism up.
b) (Without automatic clearance adjuster, with small diameter brake drums). Set the front wheel cylinder with the adjusting mechanism facing up and the rear wheel cylinder with the adjusting mechanism facing down.
c) Tighten the four bolts.
- Tightening torque: 25 Nm
4. Install the brake pipe in place and tighten the nuts by hand, then tighten them with a wrench.
- Tightening torque: 15 Nm
5. (With automatic clearance adjuster, with small diameter brake drums). Install the brake pipe retainer and tighten the bolt.
- Tightening torque: 7.8 Nm
6. Install the brake shoes and return springs.
a) Apply high temperature grease to the contact surfaces of the brake shield with the pads as shown in the figure.
b) (With automatic clearance adjuster, with small diameter brake drums). Hook the return spring onto the brake shoe from the rear inside.
c) Install both pads.
d) Using the tool, install the retaining spring, two caps and the upper shoe holder, then the lower one.
d) (With automatic clearance adjuster, with small diameter brake drums). Install the second return spring on the other side.
e) (Without automatic gap adjuster). Install two return springs.
7. Lightly sand the outer surface of the shoe lining and the working surface of the drum using sandpaper.
8. Install the brake drum in the reverse order of removal.
9. Fill the brake system reservoir with brake fluid and bleed the brake system.
10. Check for brake fluid leaks.
11. Check the clearance between the pads and the drum.
12. Install the rear wheel.