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Rear Brake Caliper Overhaul


Exploded View
Special Tools Required

Locknut wrench, 5.5 x 30 mm
 07916-6390001

Rear caliper spring compressor
 07HAE-SG00100

Snap ring pliers
 07914-SA50001
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
  • Avoid breathing dust particles.
  • Never use an air hose or brush to clean brake assemblies. Use an appropriate vacuum cleaner.

NOTE: Make sure that the caliper pins are installed correctly. Upper caliper pin B and lower caliper pin A are different. If these caliper pins are installed in the wrong location, it will cause vibration, uneven or rapid pad wear, and possibly uneven tyre wear.
  • Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water.
  • To prevent dripping brake fluid, cover disconnected hose joints with rags or shop towels.
  • Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
  • Before reassembling, check that all parts are free of dirt and other foreign particles.
  • Replace parts with new ones as specified in the illustration.
  • Make sure no dirt or other foreign matter gets in the brake fluid.
  • Make sure no grease or oil gets on the brake discs or the brake pads.
  • When reusing brake pads, always reinstall them in their original positions to prevent loss of braking efficiency.
  • Do not reuse drained brake fluid. Use only clean genuine Honda DOT 3 or DOT 4 Brake Fluid from an unopened container. Using a non-Honda brake fluid can cause corrosion and shorten the life of the system.
  • Coat the piston, the piston seal groove, and the caliper bore with clean brake fluid.
  • Use recommended greases in the rear caliper set.
  • After installing the caliper, check the brake hose and line for leaks, interference, and twisting.
  • When you apply the silicone grease, make sure not to adhere to the terminal part of connectors and surrounding switches. Also do not touch the switches and the terminal part of connector by hands or glove that adheres the silicone grease.
Disassembly
  1. Remove the caliper body.
  1. Remove the pad spring (A) from the caliper body (B).

  1. Rotate the piston (A) counterclockwise by using the locknut wrench (B), and remove the piston and piston boot (C).
    NOTE: Be careful not to damage the piston.

  1. Remove the piston seal (A) from the caliper body (B).
    NOTE: Be careful not to damage the inner surface of the cylinder wall with the tool.

  1. Install the rear caliper spring compressor (A) on the spring guide (B) inside of the caliper body.
  1. Locate a locknut (C) on the top of the shaft (D) and turn the shaft clockwise until a plate (E) touches the caliper body.

  1. Turn the locknut (A) and put it on the plate. Turn the shaft for 1/4 to 1/2 clockwise and compress the adjusting spring B.
  1. Remove the circlip (C) with the snap ring pliers (D).
  1. Depress the lower side of the locknut, tighten the upper side of the locknut and fix the position.
    NOTE: Do not displace the position of the locknut until reassembling the circlip.

  1. Remove the rear caliper spring compressor, then remove the spring guide (C), adjusting spring B, spacer (D), bearing A, adjusting bolt (E) and the cup (F).

  1. Remove the sleeve piston (A), then remove the rod (B) and the O-ring (C) from the shaft.

  1. Remove the return spring (A), then remove the lever/shaft (B) from the caliper.
    NOTE: Do not loosen a parking nut (C), with the shaft attached to the caliper. When disassembling the lever and the shaft, fix the lever to the vice and loosen the nut.
  1. Remove the shaft cover (D).

Reassembly
NOTE: When disassembling the lever and the shaft, assemble them according to the following procedure, referring to the exploded view beforehand, then install them to the caliper.
  • Install the lever and a spring washer to the shaft.
  • Apply new sealant (Loctite 569) to the threads of the parking nut and install it.
  • Fix the lever to the vice and tighten the nut.
  1. Apply silicone grease to a needle roller bearing (A) of the caliper body.
    NOTE: Check if notch of the needle roller bearing faces to the cylinder.
  1. Apply silicone grease to the seal of a new shaft cover (B), then install it to the caliper body.
  1. Apply silicone grease to the hole (C) of the shaft. Turn the hole toward the caliper, then install the lever/shaft (D) to the caliper body.
    NOTE:
    • Rotate the shaft slowly when inserting so as not to damage the seal of the shaft cover.
    • Fix the lip of the shaft cover to the groove portion of the shaft completely.
  1. Install the return spring (E).

  1. Install the rod (A) to the shaft (B) so that it turns toward the center.
  1. Install the new O-ring (C) to the sleeve piston (D).
  1. Install two pins (E) of the sleeve piston to the two holes (F) of the caliper body, so that the rod is inserted in the hole of the bottom side of the sleeve piston.

  1. Apply rubber grease to the new cup (C) and assemble to the adjusting bolt (D). Assemble the bearing A, spacer (E), adjusting spring B, and the spring guide (F), then install them into the caliper body.
    NOTE: Install the cup with the groove facing toward the bearing A.

  1. Install the rear caliper spring compressor (A) on the spring guide (B) in the caliper body and turn the shaft (C) clockwise until the plate (D) touches the locknut (E).
  1. Check that the bottom (F) of the spring guide is lower than the circlip installation groove (G) of the caliper body.

  1. Install the circlip (A) with the snap ring pliers (B).
    NOTE: Make sure the circlip securely fits in the groove of the caliper body.

  1. Apply a thin coat of silicone grease to the new piston seal (A), then install it into the groove in the caliper body.
  1. Apply a thin coat of rubber grease to the new piston boot (B), then install it into the groove in the caliper body.
  1. Apply brake fluid to the outer surface of the piston, then set the piston in place on the caliper body.

  1. Rotate the piston clockwise by using the locknut wrench (A) to install it. Make sure that the piston boot is properly positioned into the groove of the piston.
    NOTE: Be careful not to damage the piston boot when rotate the piston.

  1. Install the pad spring (A) to the caliper body (B).
  1. Install the caliper body.