Disassembly and Assembly

DX And LX:

DX and LX MODELS

LX-i And SE-i:

LX-i and SE-i Models

Caliper Piston Removal:

1. Place a wooden block or shop rag in the caliper opposite the piston, then carefully remove the piston from the caliper by applying air pressure through the brake line hole.

WARNING:
- Do not place your fingers in front of the piston.
- Do not use high air pressure; use an OSHA-approved 30 PSI nozzle.

Piston Seal And Boot Removal:

2. Remove the piston boot and piston seal.
CAUTION: Take care not to damage the cylinder.

CAUTION:
- Make sure all parts are clean before reassembly.
- Use only new replacement parts.
- Use only clean brake fluid.
- Do not allow dirt or other foreign matter to contaminate the brake fluid.
- Do not mix different brands of brake fluid.
- Avoid spilling brake fluid on painted, plastic or rubber surfaces as it can damage the finish.
- Wash spilled brake fluid off immediately with clean water.

3. Clean the piston and caliper bore with brake fluid and inspect for wear or damage.
4. Apply brake cylinder grease to a new piston seal, then install the piston seal in the cylinder groove.

Piston Seal And Boot Installation:

5. Install the piston boot.

Piston Installation:

6. Lubricate the caliper cylinder and piston with brake fluid, then install the piston in the cylinder with the dished end facing in .