What not do do When rebuilding brake calipers!! - Motorcycle-Journal Forums

TsPerformance · 12-08-2004, 07:25 PM

So i took my Front brake caliper out. disconnected the tube and let all the fluid out oops forgot to push the piston out.. No worries, i got my air blower with the rubber tip and stuck it in the brake fluid inlet.

I then blew. The piston popped (Understatment.) It Exerted itself with CONSIDERABLE force out onto my finger. It pinched me pretty bad. it looks like a cobra bit me just 2 small points...

Everyone, Before you do something think about what could happen. Airpressure+pistons in cyclinders= flying projectile.

I then stuck my pison in my lathe. I did not sand it, just cleaned ot off really nicely and then got some polishing compound and polished it to a chrome finish. i think i removed.0000000000001 of metal. it works so smooth and holds fluid GREAT!

I think there should be a mechanic section What i learned today (I will add this to suggestions.) Where us mechanics cometogether and admit the stupid mistakes we make.

LayinLo · 12-09-2004, 11:33 AM

What polishing compound did you use?

Darxide · 12-09-2004, 11:40 AM

too bad this isnt a computer forum cuz there are many countless stories i would have about when i first started mdding my sh|T

LayinLo · 12-09-2004, 11:44 AM

I can only begin to imagine..........

Darxide · 12-09-2004, 11:48 AM

quick note though, if you are ever over seas and get a printer that you need to install, make sure you click the back switch to euro setting, 220v going thru a 115v pipe is really cool if you like alot of smoke

LayinLo · 12-09-2004, 11:54 AM

I heard if you let the smoke it not only won't work anymore, but it also voids your warranty?

**87gsxrnut** · 12-09-2004, 12:03 PM

*sigh*

When rebuilding calipers:

1. Remove caliper from fork
2. Use the master cylinder to pump the pistons out
3. If you must use air, place a small block of wood between the caliper housing and the piston to avoid them "shooting out like bullets."
4. DO NOT use ANY sharp objects on the pistons or the seal surface. I used a toothpick to clean the edges and corroded seal surface the last time I did it.
5. Ensure NO foreign matter gets into the caliper when it is disassembled.
6. When reassembling, use a liberal amount of brake fluid on the seals when pressing the pistons back in.
7. Be prepared for a long bleeding session after she is assembled.
a. Bleed the banjo bolts on the master cylinder and at the caliper once you start getting pressure. Msot people forget this or don't know about it. It will save you a LOT of time because air gets trapped in there.
b. Also use a zip-tie on the lever overnight once you have completed the job to allow a complete discharge of all air bubbles.

THERE. Now SG1 - leave me alone.

- Nut

SuzukiGirl1 · 12-09-2004, 01:35 PM

Quote:

Originally Posted by 87gsxrnut

THERE. Now SG1 - leave me alone.

- Nut

Don't sass me boy!!!

Glad you're still around!!!

....come to think of it...Janis hasn't been around for quite awhile too.
Nut, is there something we should know?????

**inspiron** · 12-09-2004, 01:49 PM

I was thinking the same thing ... I guess I'll fire off an e-mail to her ...

TsPerformance · 12-09-2004, 05:31 PM

Quote:

Originally Posted by LayinLo_usmc

What polishing compound did you use?

I got all the grease off on my kerosene bath and then i used The finest compound, Not tripolli, But the white one Rouge i think.

My caliper did not detect any material removed its accurate to .0001"

12-08-2004, 07:25 PM	#1 (permalink)
TsPerformance Ditch Magnet Joined: Jun 2004 Location: Atlanta, Georgia Posts: 195	What not do do When rebuilding brake calipers!! So i took my Front brake caliper out. disconnected the tube and let all the fluid out oops forgot to push the piston out.. No worries, i got my air blower with the rubber tip and stuck it in the brake fluid inlet. I then blew. The piston popped (Understatment.) It Exerted itself with CONSIDERABLE force out onto my finger. It pinched me pretty bad. it looks like a cobra bit me just 2 small points... Everyone, Before you do something think about what could happen. Airpressure+pistons in cyclinders= flying projectile. I then stuck my pison in my lathe. I did not sand it, just cleaned ot off really nicely and then got some polishing compound and polished it to a chrome finish. i think i removed.0000000000001 of metal. it works so smooth and holds fluid GREAT! I think there should be a mechanic section What i learned today (I will add this to suggestions.) Where us mechanics cometogether and admit the stupid mistakes we make. __________________ Humans are the only animal who can have sex over the phone. ~ Dave Letterman

12-09-2004, 12:03 PM	#7 (permalink)
87gsxrnut Ho Dog Joined: Dec 2003 Bike: 867-5309 Location: Terror Lake Posts: 4,182	sigh When rebuilding calipers: 1. Remove caliper from fork 2. Use the master cylinder to pump the pistons out 3. If you must use air, place a small block of wood between the caliper housing and the piston to avoid them "shooting out like bullets." 4. DO NOT use ANY sharp objects on the pistons or the seal surface. I used a toothpick to clean the edges and corroded seal surface the last time I did it. 5. Ensure NO foreign matter gets into the caliper when it is disassembled. 6. When reassembling, use a liberal amount of brake fluid on the seals when pressing the pistons back in. 7. Be prepared for a long bleeding session after she is assembled. a. Bleed the banjo bolts on the master cylinder and at the caliper once you start getting pressure. Msot people forget this or don't know about it. It will save you a LOT of time because air gets trapped in there. b. Also use a zip-tie on the lever overnight once you have completed the job to allow a complete discharge of all air bubbles. THERE. Now SG1 - leave me alone. - Nut __________________ Person or person's unknown.

12-09-2004, 01:49 PM	#9 (permalink)
inspiron Muscle Biker Joined: Jul 2004 Bike: Blue Suzuki GSX 1400 (2003) Location: Canton Basel-Land, Switzerland (47.4493, 7.76536) Posts: 11,785	I was thinking the same thing ... I guess I'll fire off an e-mail to her ... __________________ There is nothing worse than aggressive stupidity. - Johann Wolfgang von Goethe blog: gsx1400

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12-09-2004, 11:33 AM	#2 (permalink)
LayinLo Flipper ( Don't Ask ) Joined: Jul 2004 Bike: Crunchy 02 GSX-R 750 Location: Alabama Posts: 3,936	What polishing compound did you use?

12-09-2004, 11:40 AM	#3 (permalink)
Darxide Banned Joined: Nov 2004 Location: Panama City Posts: 850	too bad this isnt a computer forum cuz there are many countless stories i would have about when i first started mdding my sh\|T

12-09-2004, 11:44 AM	#4 (permalink)
LayinLo Flipper ( Don't Ask ) Joined: Jul 2004 Bike: Crunchy 02 GSX-R 750 Location: Alabama Posts: 3,936	I can only begin to imagine..........

12-09-2004, 11:48 AM	#5 (permalink)
Darxide Banned Joined: Nov 2004 Location: Panama City Posts: 850	quick note though, if you are ever over seas and get a printer that you need to install, make sure you click the back switch to euro setting, 220v going thru a 115v pipe is really cool if you like alot of smoke

12-09-2004, 11:54 AM	#6 (permalink)
LayinLo Flipper ( Don't Ask ) Joined: Jul 2004 Bike: Crunchy 02 GSX-R 750 Location: Alabama Posts: 3,936	I heard if you let the smoke it not only won't work anymore, but it also voids your warranty?

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