Author Topic: Brake caliper strip and rebuilds.  (Read 5345 times)

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Offline nsrnick

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Brake caliper strip and rebuilds.
« on: March 28, 2010, 06:23:36 PM »
First things first, brake fluid, 30 year old asbestos filled pads, all manner of crud from the road is dangerous. I use latex gloves, safety glasses and a mask for ALL dissmantling work. The choice is yours but i highly recommend you do the same.

Secondly, this is NOT a "how to" and i  [and the club] accept no responsibilty for any damage to you or bike or anything else, this is just the way i do rebuilds.

If your in any doubt of your ability to complete the job i suggest you stop and have a beer



I start by clamping the caliper mount in the vice and then remove the rear brake line to free off the master cylinder, next i undo the through bolt [12mm socket] and withdraw fully, making sure i get the large spacer between the caliper and mount and put the mount to one side.The bush in the caliper can and does seize solid, i use a press to remove it and it can take up to 10 ton to make it "pop"



Arse....The bleed nipple has sheard from not being used, it is worth cracking these open on your bike, once a month.





Ok, out with the drill bits! i use a 6.8mm good quality. I buy in bulk and never sharpen them, used three or four times then bin fodder. This is not the correct angle, but i follow the path of the old bleed nipple and very short bursts of the drill, a little at a time and keep removing the bit and checking for depth.





Eventually the nipple seat can be seen, it will "spin" on the caliper body as the seal is broken, this is the time to stop, some rust will also be evident.





I then clean out the remaining bits of thread of the bleed nipple and re-tap m8 x 1.25

 



Looks a little grim in there but once blasted it will be ok.





Install a new bleed nipple and nip it up.

 



I then bleed it up on the bench as normal [on the bike say] and get good pressure once fully bled.





Here you can see the state of the piston as it comes out of the caliper bore [this ones not too bad tbh



I now have this little lot on the bench, i take lots of photos as this makes it easier once all the parts are re-finished, they look very different after a couple of weeks and different colours.

Now is also the time to repair any marks in the body or mounting bracket, i use a fine file, the trick here is not to remove too much alloy as to alter the shape of the job.

Thats the strip down of the rear brake, the front is a repeat of the above.

Offline SupeRDel

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Brake caliper strip and rebuilds.
« Reply #1 on: March 29, 2010, 02:08:06 AM »
Nice set of instructions.



I have done the calipers on my 400C and used the grease gun method. I put a grease nipple on the blled nipple hole and use a grease gun to pump the piston out. A bit messy but I wash everything in the works degrease tank after.



When I refit the bleed nipples I just nip them - no more than a tweek. They are not a load bearing part requiring someone hanging on a spanner to tighten.

(I call it the wheelnut syndrome)



I also spray a bit of WD40 on the thread a few days before attempting to undo it.
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Offline mervin

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« Reply #2 on: March 29, 2010, 04:33:52 AM »
i Usually put a little copaslip on the nipple threads

merv
Motorcycling is not, of itself, inherently dangerous. It is, however, extremely unforgiving of inattention, ignorance, incompetence, or stupidity"

Offline Paul Dawkins

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« Reply #3 on: March 30, 2010, 12:06:30 PM »
Looks good Nick

Hope you can remember how they go back together
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Offline Mr. Wiring Wizard

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« Reply #4 on: March 30, 2010, 01:53:43 PM »
So do I! He"s got my XS1100 twin calipers too.

Offline nsrnick

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« Reply #5 on: April 02, 2010, 12:55:03 PM »
 
Quote from: edrfranklin
So do I! He"s got my XS1100 twin calipers too.




They done chap  

Offline Mr. Wiring Wizard

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« Reply #6 on: April 02, 2010, 01:14:25 PM »
Lovely!  

Offline theholybull

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« Reply #7 on: April 04, 2010, 10:46:53 PM »
I had mine bead blasted and powder coated with a metallic silver. Im just glad my bleeder came out easily.
How hard can it be?

Offline nsrnick

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« Reply #8 on: April 25, 2010, 04:23:02 PM »
Ok. the front caliper/hanger is all finished, no pics coz me pluckin mem cards donald ducked, will sort that on the rear.

Offline Johnny

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« Reply #9 on: August 29, 2010, 06:54:12 AM »
Bumped up for Jock .



Can we have an update Nick ? Jock"s tells me he"s never done this sort of work , but no to tell anyone    he"s a tad embarassed  
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Offline nsrnick

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Brake caliper strip and rebuilds.
« Reply #10 on: August 29, 2010, 08:03:12 AM »
Will be doing a couple of e/f calipers later today for this very section.

Offline RD JOCK

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« Reply #11 on: August 29, 2010, 08:03:13 AM »
 
Quote from: Johnny
Bumped up for Jock .



Can we have an update Nick ? Jock"s tells me he"s never done this sort of work , but no to tell anyone    he"s a tad embarassed  




     
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Offline Med

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« Reply #12 on: August 30, 2010, 07:57:15 AM »
good work