Note: The assembled parts should look like the picture.
With front disc brakes
With front drum brakes
1. Assemble the wheel cylinder.
a) Apply lithium-based grease to the parts as shown in the figure.
b) Assemble the cylinder.
Note: Assemble in the reverse order of removal.
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2. Install the wheel cylinder.
a) Install the cylinder on the brake shield and tighten the two bolts.
- Tightening torque: 14 Nm
b) Connect the brake line.
- Tightening torque: 15 Nm
c) Fit the bleeder fitting.
3. Install the adjuster spring support onto the brake shield and tighten the nut.
- Tightening torque: 34 Nm
4. Install the front and rear pads and spacer plate.
a) Apply high temperature grease as shown in the figure.
b) Connect the parking brake cable to the parking brake shoe lever.
c) After bringing the piston rod into contact with the rear shoe, install it in place as shown in the figure. Then install the retaining spring, caps and holder.
d) Install the brake shoe spacer plate.
d) Install the front shoe in the same way.
5. Install the regulator.
a) Apply high temperature grease as shown in the figure.
b) Install the regulator.
6. Install two anchor springs.
7. Install the retainer, cable guide, adjuster cable and return springs.
a) Install the retainer.
b) (With front disc brakes) Install the cable guide and adjuster cable.
c) Using the tool, install the front return spring and then the rear one.
8. (With front disc brakes) Install the regulator lever.
a) Install the anchor spring on the rear shoe.
b) Hook the cable to the regulator lever and install the lever.
c) Hook the regulator lever spring so that the regulator lever is held by this spring.
9. Check the operation of the automatic regulator.
a) Press the adjuster cable as shown in the figure and release. Make sure the adjusting bolt turns.
If the bolt does not turn, check that the rear shoe is installed correctly.
b) Turn the regulator to the smallest possible distance.
c) Install the drum.
d) Turn the drum in the direction shown in the figure and press the brake pedal. Repeat the procedure several times.
10. (With front drum brakes) Adjust the brake pad clearance.
a) Loosen the regulator spring support mounting bolt.
b) Temporarily install the brake drum and spread the shoes by turning the adjuster until the drum stops.
c) Tighten the support mounting bolt.
- Tightening torque: 5.9 Nm
d) Turn the regulator until the drum rotates freely and then another three teeth.
11. Check the clearance between the pads and the drum.
a) Remove the drum.
b) Measure the inside diameter of the brake drum and the diameter of the brake shoes. Check that the difference between these diameters corresponds to the correct shoe clearance.
- Brake pad clearance: 0.6 mm
If not, check the parking brake system.
12. Lightly sand the outer surface of the shoe lining and the working surface of the drum using sandpaper.
13. Install the brake drum and tighten the screw.
14. Fill the brake system reservoir with brake fluid and bleed the brake system.
15. Check for brake fluid leaks.
16. Install the rear wheel.