Operation CHARM: Car repair manuals for everyone.
Manuals through 2025 now available!

Our trusted friends have launched a new website named LEMON, which has newer manuals. It also contains all the CHARM manuals.

LEMON is the spiritual successor to CHARM, I recommend you try it!

Link: lemon-manuals.la or lemon-manuals.org.ua

(Some people have issue connecting. LEMON is investigating. For now, use Firefox or change your DNS server)

Or, hide this message: temporarily or permanently

Reassembly








BRAKE: FRONT BRAKE: REASSEMBLY

REASSEMBLY

1. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
2. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
3. INSTALL PISTON SEAL





(a) Apply lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal onto the disc brake cylinder.
NOTICE: Securely install the piston seal into the groove of the disc brake cylinder.

4. INSTALL FRONT DISC BRAKE PISTON





(a) Apply lithium soap base glycol grease to the piston and a new cylinder boot.
(b) Install the cylinder boot onto the piston.
NOTICE: Securely install the cylinder boot into the groove of the piston.

(c) Install the piston into the disc brake cylinder.
NOTICE: Do not forcibly install the piston into the disc brake cylinder.

5. INSTALL CYLINDER BOOT





(a) Install the cylinder boot into the disc brake cylinder.
NOTICE: Securely install the cylinder boot into the groove of the disc brake cylinder.

(b) Using a screwdriver, install a new set ring.
NOTICE:
- Securely install the set ring into the groove of the cylinder boot.
- Do not damage the cylinder boot.