Page 1
15. REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER
15-0
GRAND DINK 125/15 0
15
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REAR BRAKE/REAR FORK/REAR WHEEL/
REAR SHOCK ABSORBER
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SCHEMATIC DRAWING ---------------------------------------------- 15-1
SERVICE INFORMATION -------------------------------------------- 15-2
TROUBLESHOOTING ------------------------------------------------- 15-2
REAR BRAKE ----------------------------------------------------------- 15-3
REAR FORK ------------------------------------------------------------- 15-4
REAR WHEEL ---------------------------------------------------------- 15-4
REAR SHOCK ABSORBER-------------------------------------------- 15-5
15
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15. REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER
15-1
GRAND DINK 125/15 0
SCHEMATIC DRAWING
Page 3
15. REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER
15-2
GRAND DINK 125/15 0
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• When performing the services stated in this section, the engine and exhaust muffler must be cold
to avoid scalding.
• During servicing, keep oil or grease off the brake pads and brake disk.
SPECIFICATIONS
Item
Standard (mm)
Service Limit (mm)
Rear wheel rim runout
æ
2.0
Rear shock absorber spring free length
232.9
226
Rear brake disk thickness
3.5_ 3.8
3.0
Rear brake disk runout
æ
0.30
Rear brake master cylinder I.D.
12.700_ 12.743
12.755
Rear brake master cylinder piston O.D.
12.657_ 12.684
12.645
Rear brake caliper cylinder I.D.
25.400_ 25.45
25.45
Rear brake caliper piston O.D.
25.335_ 25.368
25.30
TORQUE VALUES SPECIAL TOOLS
Exhaust muffler lock bolt 29.4_ 39.2N-m Rear shock absorber remover
Rear axle nut 78.4_ 98N-m Shock absorber spring compressor
Rear shock absorber lower mount bolt 19.6_ 29.4N-m
Rear shock absorber upper mount bolt 39.2N-m
Rear damper lock nut 14.7_ 24.5N-m
(apply locking agent)
Rear brake caliper bolt 19.6_ 29.4N-m
TROUBLESHOOTING
Rear wheel wobbling Poor brake performance
• Bent rim • Air in brake system
• Faulty tire • Deteriorated brake fluid
• Axle not tightened properly • Contaminated brake pad surface
• Worn brake pads
Soft rear shock absorber • Clogged brake fluid line
• Weak shock absorber spring • Deformed brake disk
• Damper oil leaks • Unevenly worn brake caliper
Rear wheel noise
• Worn rear wheel axle bearings
• Worn rear fork bearings
• Deformed rear fork
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15. REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER
15-3
GRAND DINK 125/15 0
REAR BRAKE
REAR BRAKE CALIPER REMOVAL
First remove the exhaust muffler. (!2-6)
Remove the rear brake fluid tube bolt and
disconnect the brake fluid tube.
Remove the two bolts attaching the rear brake
caliper.
Remove the rear brake caliper.
INSPECTION
Inspect the brake pads and brake disk.
Visually check the brake pad thickness and it
should not exceed the wear indicator mark.
Measure the brake disk thickness.
Service Limit: 3.0mm replace if below
DISASSEMBLY
Disassemble the rear brake caliper. (!14-11)
Inspect and assemble the rear brake caliper .
(!14-12)
Note: The rear brake caliper and front brake
caliper have the same specification.
INSTALLATION
Install the brake caliper to the rear fork and
tighten the two bolts.
Torque: 24.5_ 34.3N-m
Connect the brake fluid tube to the brake
caliper and tighten the fluid tube bolt.
Fill the brake reservoir with the specified
brake fluid and bleed air from the brake
system. (!14-10)
When installing the brake fluid tube, be
sure to install the two copper sealing
washers.
＊
When removing the brake fluid tube, use
shop towels to cover plastic parts and
coated surfaces to avoid damage.
＊
Brake Disk
Fluid Tube Bolt
Brake Pads
Bolts
Fluid Tube Bolt
Copper Washers
Bolts
Brake Caliper
Wear Indicator Mark
Page 5
15. REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER
15-4
GRAND DINK 125/15 0
REAR FORK
REMOVAL
Remove the exhaust muffler. (!2-6)
Remove the rear brake caliper. (!15-3)
Remove the right rear shock absorber lower
mount bolt.
Remove the rear axle nut and remove the
collar.
Remove the rear fork.
The installation sequence is the reverse of
removal.
Turn the inner race of each bearing with your
finger to see if they turn smoothly and
quietly.
Also check if the outer race fits tightly in the
hub.
Replace the bearings if the races do not turn
smoothly, quietly, or if they fit loosely in the
hub.
REAR WHEEL
REMOVAL
Remove the exhaust muffler. (!2-6)
Remove the rear brake caliper. (!15-3)
Remove the rear fork.
Remove the rear axle collar.
Remove the rear wheel.
INSPECTION
Measure the rear wheel rim runout.
Service Limits:
Radial: 2.0mm replace if over
Axial: 2.0mm replace if over
Shock Absorber Lower Mount Bolt
Collar
Axle Nut
Rear Axle Collar
Rear Fork
Rear Brake Disk
Page 6
15. REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER
15-5
GRAND DINK 125/15 0
INSTALLATION
The installation sequence is the reverse of
removal.
Torque:
Rear shock absorber lower mount bolt:
19.6_ 29.4N-m
Rear axle nut: 78.4_ 98N-m
ADJUSTABLE REAR CUSHION
To suit scooter behaviour to load condition
rear cushion could be adjusted in spring
prelocad.
It is possible to adjust rear cushion in three
positions:
A position “soft”
B position “medium”
C position “hard”
When you adjust rear cushion, the spring
preload of rear cushions must be the same.
REAR SHOCK ABSORBER
REMOVAL
Remove the rear carrier and hand rail. (!2-3)
Remove the met-in box. (!2-3)
Remove the two air cleaner bolts.
Remove the rear shock absorber upper mount
bolt.
Remove the right/left rear shock absorber
upper and lower mount bolts.
Remove the right and left rear shock
absorbers.
INSPECTION
Install the rear shock absorbers in the reverse
order of removal.
Torque:
Upper Mount Bolt: 39.2N-m
Lower Mount Bolt: 19.6_ 29.4N-m
Shock Absorber Lower Mount Bolt
Axle Nut
A
Upper Mount Bolts
Brake Caliper Bolts
Lower Mount Bolts
B
C
123
4
5
Upper Mount Bolts
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