Resend my activation email : Register : Log in 
BCF: Bike Chat Forums


Stuck break calipers. Help!

Reply to topic
Bike Chat Forums Index -> The Workshop
View previous topic : View next topic  
Author Message

LCK
L Plate Warrior



Joined: 15 May 2015
Karma :

PostPosted: 22:27 - 15 May 2015    Post subject: Stuck break calipers. Help! Reply with quote

Weaker than usual front breaks on Lexmoto Arizona, (double cylinder, + yes I know its a Chinese bike...)
I have a fair bit of mechanical confidence, so decided to remove caliper, clean pads, etc. after watching a few videos. Cylinders were well cruddy and rusty, so i gave them a scrub, pumped break gently to check movement.

One cylinder moved out a bit, the other a fair way out, but not popped out (whew..). But,.. neither of them will move or twist or anything. Tried gentle persuasion with plumbing wrench.

Am I right in thinking the next stage involves a big C clamp to push them back in? I also used very fine grade sandpaper and WD40 on the pistons only (advised by MCN tutorial), they still have a little corrosion.)

1. Do I push one cylinder, until even with other one, before clamping both and pushing back together?(I know if you push one, the other moves out.

2. Will I need to bleed the brakes/ open the valve to do this? Some say yes, (HOW THE HELL DO YOU QUICKLY OPEN AND CLOSE THE BLEED VALVE WHILE CLAMPING?) some say no in other forums. Confused.

3. Is a clamp the best way to do this?

Thanks in advance for wise words, I realise it is dangerous to fiddle with breaks if inexperienced, but thorough testing will follow on a quiet road. Gotta learn how to service them someday! Very Happy
 Back to top
View user's profile Send private message Send e-mail You must be logged in to rate posts

Rogerborg
nimbA



Joined: 26 Oct 2010
Karma :

PostPosted: 22:49 - 15 May 2015    Post subject: Reply with quote

Take the top off your master cylinder reservoir or at least loosen it to allow air out.

The pistons should push back in by hand.

If they need more than that then it's likely that the seals are swollen or there's corrosion or dried up brake fluid in behind them.

If you're going to do it properly, the pistons and seals will have to come out and you'll need to clean behind the seals and possibly replace them. A slightly blunted dental pick is ideal for fishing them out and cleaning out the grooves - you can get them in some supermarkets.
____________________
Biking is 1/20th as dangerous as horse riding.
GONE: HN125-8, LF-250B, GPz 305, GPZ 500S, Burgman 400 // RIDING: F650GS (800 twin), Royal Enfield Bullet Electra 500 AVL, Ninja 250R because racebike
 Back to top
View user's profile Send private message You must be logged in to rate posts

RhynoCZ
Super Spammer



Joined: 09 Mar 2012
Karma :

PostPosted: 23:09 - 15 May 2015    Post subject: Reply with quote

What Roger says and NEVER use any inappropriate tools, such as pliers to push the pots in or pull them out. Damaging the pots is the last thing you'd want to do. Thumbs Up

Loosen up every single bolt, that you're gonna need to be loose later, before you take the caliper of the bracket/fork. Then use the MC to push them all out. Do it equally, put something between the pots to do so.
____________________
'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor
 Back to top
View user's profile Send private message You must be logged in to rate posts

DRZ4Hunned
World Chat Champion



Joined: 15 Apr 2014
Karma :

PostPosted: 23:18 - 15 May 2015    Post subject: Reply with quote

Doing this job myself ATM, what a pain in the arse! Took the calliper off as I watched some guy on youtube do it but couldn't get mine out manually, so had to re-attach and re-bleed to try and pump them out hydraulically. Managed to get the brakes working but they'd only pump out partially, think the system may need bleeding again.
____________________
DRZ400-SM
FZS600
 Back to top
View user's profile Send private message You must be logged in to rate posts

RhynoCZ
Super Spammer



Joined: 09 Mar 2012
Karma :

PostPosted: 23:35 - 15 May 2015    Post subject: Reply with quote

DRZ4Hunned wrote:
Doing this job myself ATM, what a pain in the arse! Took the calliper off as I watched some guy on youtube do it but couldn't get mine out manually, so had to re-attach and re-bleed to try and pump them out hydraulically. Managed to get the brakes working but they'd only pump out partially, think the system may need bleeding again.


Yep, always use your brain before you use your tools. Thumbs Up
____________________
'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor
 Back to top
View user's profile Send private message You must be logged in to rate posts

Pigeon
World Chat Champion



Joined: 27 Sep 2012
Karma :

PostPosted: 23:53 - 15 May 2015    Post subject: Reply with quote

Also, don't get WD40 near the rubber seals. They absorb it and expand massively, completely blocking the piston........not that I've done this Whistle
 Back to top
View user's profile Send private message You must be logged in to rate posts

Kwakki Si
Trackday Trickster



Joined: 08 Jan 2012
Karma :

PostPosted: 11:31 - 16 May 2015    Post subject: Re: Stuck break calipers. Help! Reply with quote

LCK wrote:
Weaker than usual front breaks on Lexmoto Arizona, (double cylinder, + yes I know its a Chinese bike...)
I have a fair bit of mechanical confidence, so decided to remove caliper, clean pads, etc. after watching a few videos. Cylinders were well cruddy and rusty, so i gave them a scrub, pumped break gently to check movement.

One cylinder moved out a bit, the other a fair way out, but not popped out (whew..). But,.. neither of them will move or twist or anything. Tried gentle persuasion with plumbing wrench.

Am I right in thinking the next stage involves a big C clamp to push them back in? I also used very fine grade sandpaper and WD40 on the pistons only (advised by MCN tutorial), they still have a little corrosion.)

1. Do I push one cylinder, until even with other one, before clamping both and pushing back together?(I know if you push one, the other moves out.

2. Will I need to bleed the brakes/ open the valve to do this? Some say yes, (HOW THE HELL DO YOU QUICKLY OPEN AND CLOSE THE BLEED VALVE WHILE CLAMPING?) some say no in other forums. Confused.

3. Is a clamp the best way to do this?

Thanks in advance for wise words, I realise it is dangerous to fiddle with breaks if inexperienced, but thorough testing will follow on a quiet road. Gotta learn how to service them someday! Very Happy


You need to remove both pistons and split the calliper and clean it out, replace all the seals and grease up with red rubber grease and then the pistons should move nice and freely and be able to push in by hand, easy job and takes a couple of hours, plenty of youtube vids on it.
____________________
MOD1 passed 26/01/12... MOD2 passed 08/02/12
My current ride: ZX6R NINJA G2, The GREEEEN one!
Is it a bird? Is it a plane? No, it's a mother fucking motorbike!
 Back to top
View user's profile Send private message Send e-mail You must be logged in to rate posts

kramdra
World Chat Champion



Joined: 28 Oct 2010
Karma :

PostPosted: 14:05 - 16 May 2015    Post subject: Re: Stuck break calipers. Help! Reply with quote

LCK wrote:
...Tried gentle persuasion with plumbing wrench.

Am I right in thinking the next stage involves a big C clamp to push them back in?

I also used very fine grade sandpaper



1) good way to ruin pistons

2) no. only spotless, clean pistons can be pushed in unless you want to ruin seals.

3) very fine abraisives ~1500grit can be used too polish stainless pistons, but not with calliper assembled.

pop the pistons out, clean them, clean the seals in fresh brake fluid, clean the seal groves. Check the seals for any damage, if so replace. reassemble.

Bleeding takes about 5 mins, reverse fill with a syringe, crack open the MC banjo to bleed.
 Back to top
View user's profile Send private message You must be logged in to rate posts

LCK
L Plate Warrior



Joined: 15 May 2015
Karma :

PostPosted: 15:19 - 16 May 2015    Post subject: Reply with quote

Thanks for all the tips.
What worked= opened up main bleed valve, table to rest caliper on, screwdriver neck to press down pistons, topped up break fluid (in the nick of time!!)
Road test = great success, functioning brilliantly. Thumbs Up Thumbs Up Thumbs Up Mr. Green
 Back to top
View user's profile Send private message Send e-mail You must be logged in to rate posts

Kwakki Si
Trackday Trickster



Joined: 08 Jan 2012
Karma :

PostPosted: 16:53 - 16 May 2015    Post subject: Reply with quote

LCK wrote:
Thanks for all the tips.
What worked= opened up main bleed valve, table to rest caliper on, screwdriver neck to press down pistons, topped up break fluid (in the nick of time!!)
Road test = great success, functioning brilliantly. Thumbs Up Thumbs Up Thumbs Up Mr. Green


Why not just give them a overhaul anyways? god knows what condition the seals are in.
____________________
MOD1 passed 26/01/12... MOD2 passed 08/02/12
My current ride: ZX6R NINJA G2, The GREEEEN one!
Is it a bird? Is it a plane? No, it's a mother fucking motorbike!
 Back to top
View user's profile Send private message Send e-mail You must be logged in to rate posts

LCK
L Plate Warrior



Joined: 15 May 2015
Karma :

PostPosted: 18:19 - 16 May 2015    Post subject: Reply with quote

Kwakki Si wrote:
LCK wrote:
Thanks for all the tips.
What worked= opened up main bleed valve, table to rest caliper on, screwdriver neck to press down pistons, topped up break fluid (in the nick of time!!)
Road test = great success, functioning brilliantly. Thumbs Up Thumbs Up Thumbs Up Mr. Green


Why not just give them a overhaul anyways? god knows what condition the seals are in.


It is my BF's bike, if he wants to strip them he can Smile
 Back to top
View user's profile Send private message Send e-mail You must be logged in to rate posts
Old Thread Alert!

The last post was made 11 years, 133 days ago. Instead of replying here, would creating a new thread be more useful?
  Display posts from previous:   
This page may contain affiliate links, which means we may earn a small commission if a visitor clicks through and makes a purchase. By clicking on an affiliate link, you accept that third-party cookies will be set.

Post new topic   Reply to topic    Bike Chat Forums Index -> The Workshop All times are GMT + 1 Hour
Page 1 of 1

 
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum
You cannot attach files in this forum
You cannot download files in this forum

Read the Terms of Use! - Powered by phpBB © phpBB Group
 

Debug Mode: ON - Server: birks (www) - Page Generation Time: 0.09 Sec - Server Load: 0.9 - MySQL Queries: 13 - Page Size: 74.27 Kb