Thundercat 'Blue Spot' caliper rebuild

[jay_666]

Having trouble removing the pistons from my thundercat's brake calipers on the front. The calipers do not split apart and i cant see how to remove the pistons as they oppose eachother One of them is also seized in place and wont budge.

My plan is to strip the calipers, clean up the pistons and fit new seals.

Any held would be greatly appreciated, as im pretty stuck at the moment.
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[Pete.]

Never touched them but don't the blue bits un-screw? As for the stuck piston, pump it out with the brake lever and clean it.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[Wafer_Thin_Ham]

[jay_666]

this? --> https://www.billetbikebits.com/shop/index.php?main_page=product_info&products_id=82


Ive been told the blue spots screw inwards though?as in towards where the rotor would be...
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[druidsam]

having recently rebuilt my thundercat calipers, the best advise i can give you is this, remove the calliper from the fork leg and take the brake pads out , put a piece of wood in the caliper where the pistons are and slowly pump the pistons out using the brake lever, when the pistons are ALL touching the wood replace it with a thinner piece and pump the pistons out some more.

doing it this way ensures that if one or more pistons are sticking you will still be able to get them out relatively easy

when replacing the seals make sure the grooves are spotless, the slightest bit of crud in these stops the new seal from seeting properly and makes it very difficult to refit the piston
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[jay_666]

Thing is, i dont understand how to remove all of the pistons. They come out together, and end up face to face as they oppose each other, leaving no room for removal. and one one is out, there is no pressure in the system to push the rest out.
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CBT - Done | Theory - Passed | Test - 4th Oct [PASSED!]
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[el_oso]

you may need to top up the brake fluid level. check there is fluid in the reservoir.
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Duke 390
Previous: '05 XR125L | '96 XJ600S Diversion |'05 Suzuki GSXR1000 | '05 Honda CBR125-R | '97 YZF 600R Thundercat | '11 Honda CBR250
Car: Jeep Wrangler 4.0L

[jay_666]

fluid levels are fine
____________________
CBT - Done | Theory - Passed | Test - 4th Oct [PASSED!]
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[druidsam]

[el_oso]

once you have lost all pressure then you should be able to pull the pistons out by wiggling them around
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Duke 390
Previous: '05 XR125L | '96 XJ600S Diversion |'05 Suzuki GSXR1000 | '05 Honda CBR125-R | '97 YZF 600R Thundercat | '11 Honda CBR250
Car: Jeep Wrangler 4.0L

[jay_666]

I've read around and people refer to using 'clamps' to hold the pistons. Space is so limited i dont see how you can get a g-clamp in the caliper at all.

Also, the pistons are really stiff to press back into the caliper. some of the dust seals are starting to expose themselves and im worried if i push one piston out using the brake lever, i wont be able to get the others out due to them being so stiff.
____________________
CBT - Done | Theory - Passed | Test - 4th Oct [PASSED!]
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[druidsam]

[jay_666]

by 'vice grips' do you mean mole grips?
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[Vincent]

[jay_666]

Yeah, thats why i ask. I dont really want to be touching those pistons with anything if i can help it...
____________________
CBT - Done | Theory - Passed | Test - 4th Oct [PASSED!]
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[Vincent]

Don't you need to undo the blue bit in the middle?

[Noxious89123]