XJ600s Front Caliper Service

[Twisted2004]

The front brake on my XJ600s is terriable!

If it rains and the front disc gets a little rusty, it seems like it takes ages for the disc to become clear again, which in my opinion - AINT RIGHT!

So far i've changed the front brake line for a braided goodridge line and completely renewed the fluid.

Although this did make a little difference it wasnt substantial!

So hopefully this weekend im going to strip down the entire caliper and give everything a good seeing to! I've purchased some new piston seals as i may get a bit crazed and tear up the old ones!

I've had a look at the guides that people have posted and they seem very useful!

I have striped down and serviced my front caliper on my DT125, so i'm thinking everything should be very similiar other than the XJ has two pistons, i think??

Also gonna change the front pads.

Should be okay, any last minute tips n tricks?
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[Kickstart]

Hi

The pistons should come out easy enough. Just make sure they come out together.

However also check the pins that the caliper slides on. Quite probable that one of these is sticking.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Twisted2004]

[Kickstart]

Hi

Just because the least seized will come out first, leaving the more stuck out to be a real pain to get out.

If you try and pull them out with pliers you will wreck them (probably) and I assume you do not have a compressor to supply air to blow them out. As such the easiest way is to just use the brake system itself to push them out, and getting them both out at the same time saves cleaning up one piston, replacing it then bleeding the system just to get the other piston out.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Twisted2004]

[Kickstart]

Hi

Yep, pretty much. May be worth putting the caliper in a plastic bag while you pump the pistons out, this way it limits the amount of fluid going everywhere. Once the pistons are out you can disconnect the caliper if it makes life easier for you. Use something like an old pad to press against the pistons to keep them coming out at the same rate. One will come out marginally before the other, but by that stage the other should be fairly easy to remove with minimal effort.

The seals may or may not be reuseable. Common problem is corrosion in the groove the seals sit in, pushing the seals hard onto the piston.

However, check the pins it slides on first. May well be that is the problem and they are easy to clean up without opening the caliper up and spilling fluid.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Twisted2004]

[Twisted2004]

After doing a service on my bike, i decided to attack the front caliper.

I done what u said about using the system to get the pistons out. Turn outs that one piston had siezed and wasnt budging!

Managed to get it out cleaned afterthing up, replaced the seals and now all is fine! Although the brakes are still a bit spongy, but i need to replace the bleed nipple because its nearly completely rounded off! So when i get a new one i'll rebleed once again and make sure there is no air in there!

I've got some pics on my phone, i'll post them when i can get them off!

Thanks again for the help.
____________________
Previous : DT125 > XJ600S > YZF1000R > Honda CBR1000RR-8 Fireblade (White) - Stolen > Honda CBR125R> Honda CBR1000RR-8 Fireblade (Red)
Current : Ducati Multistrada Pikes Peak (For Sale)

[Kickstart]

Hi

If you have bled the system through from empty then it is easy to get some air at the top of the system, around the banjo bolt into the master cylinder. Wrap a cloth around the banjo bolt, pull the brake hard and crack off the banjo bolt a bit and retighten it (quickly). This should get any air out.

The cloth is important to stop any fluid that comes out squirting over the bodywork.

All the best

keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing