Can somebody post a tutorial on how to change front brake?

I'm a new to this site and I just got my 1982 xj650 today with 6051 original miles. However, the brake squeels. Could it be the pads? Original owner told me, the pads and everything on this bike is original. Please help.

 

Low mileage on brakes is not necessarily a good thing. Brake pads draw moisture from the air, deteriorate and crumble. Rear brake shoes delaminate from their frames. Hoses dry out and become extra-spongy; the brake fluid loses its ability to withstand heat. Everything should be replaced.

My '83 Seca 550 only had 7100 miles on it when I got it; the entire brake system still had to be rebuilt. Shoes, pads, caliper seals, master cylinder cleaned/rebuilt and new lines.

Brakes are one area where you CANNOT take shortcuts. Gotta do it.

If everything is original you better start looking at tires too. I wouldn't ride on 27-year old tubeless tires.

I know from experience it's a heartbreaker resurrecting a low-mileage bike this old; it really sucks having to replace things that have "aged-out" rather than worn out, but it's worth it. Once you're done you'll have a brand-new 27 year old bike. THAT'S a really GOOD feeling.

As for the tutorial, which 650? The Seca and Max have completely different front brake systems. You've got to do more than replace pads anyway.

 

Re: Can somebody post a tutorial on how to change front brak

Fitz gave you good advice. Get the factory service manual and do ALL the maintenance in the maintenance section. Replace tires that are 5 years or older.

Getting front pads off an XJ650 is just about the easiest job in the world:

Pivot the caliper back and forth to push the piston back in.

There is a pin at the bottom of the caliper, with a spring clip between the caliper body and the outside pad. Squeeze the ears on the clip together and the pin will pull out - pads will probably fall out as you do it.

If the pads aren't shot they'll appear to have worn unevenly. They're supposed to look that way - friction material is wedge shaped.

 

Re: Can somebody post a tutorial on how to change front brak

Thanks Bigfitz for that wonderful tip. I am deeply saddened to hear all things that I have to do to make it as a daily rider. But, you're right, it's better to do them now.
The bike is a maxim. The bike sat/idled for 1.5 years. But the owner told me that he rode the bike every summer prior to storing it.
I rode her around the culdesac and the rear brake feels really good, it grabbed. The front, however, is spongy and squeels.
I inspected the front brake pads, there's an un-even wear. One side is thicker than the other. hmmmmn...I guess time to rebuild the whole break system. I just don't have the know how, but I'm pretty good in following instructions/diagrams.
Mahalo and have a good weekend.

 

Re: Can somebody post a tutorial on how to change front brak

Unfortunately, the bike didn't came with the service manual. Is there a site when I can download the manual and the repair manual? And I've been hearing about this slip oil adapter thing. I saw one from NAPA's catalog. Will this work? Is it the same as Chacal's?

 

Not sure about the oil filter thing from NAPA.

Do us all a favor, add your location to your profile and your bike info to your signature so we'll have that info at hand when ask questions.

Please don't just dismiss maintenance because it didn't sit undisturbed for all that time. At 6051 miles you're 3051 miles overdue for the first valve adjustment unless PO has documented proof he did it.

You have an awesome opportunity here: to build yourself a brand new 27 year old bike. Do it right, it's more labor than parts. The results are very satisfying. (Look in my gallery, the black bike had only 7100 on it when I got it.)

 

Re: Can somebody post a tutorial on how to change front brak

As I said in my earlier post - the pads are supposed to be like that. If you look at the back side of the thin pad it'll be thick and the other one will be thin at back. The caliper approaches the disc at an angle and the pads are wedge shaped to compensate. When both pads are the same thickness they're worn out.

Chacal sells the factory manual. He will be your best friend.

 

Re: Can somebody post a tutorial on how to change front brak

arrrgh...I sprayed and soaked the master cyl screws(I saw someone had a hard time removing them) for two days. When i attempted to loosen them up, I struggled with one, but loose now. the other one, however, is rounded off. I'm hoping ez out or some sort of screw extractor will provide some help. any tips? Thanks All

82 Xj650
Portland, OR.

 

I used the Craftsman small screw extractor on one screw on each of my bikes' M/Cs. Worked so well Bob Vila got a warm fuzzy and he doesn't even do their promos anymore.

Get some Kroil you will need it eventually if not now. http://www.kanolabs.com/google/

It really does work when nothing else will.

 

I used a small straight slot bit on my rounded out phillips screw. I knocked it in there with a hammer just enough to wedge it in what was left of the phillips slots. Then it turned out since the screw driver couldn't slip. New screws went back in.

 

Thanks guys! I used the no.2 extractor and it came off! Since my rebuild kits are not yet here, I flushed all the old fluids out--really dirty, dark brown with bunch of particles. i used the whole 12oz bottle to get her cleaned up.

The break feels really good now, not spongy. The pads are in a good condition but will replace them when I have all the kits to rebuild the M/C, and the Cal. and squeeling is almost gone.

I replaced the oil/filter too. The drain plug/magnet had some sludge/thick particles. The supposedly OEM oil filter that's there is made in the Philippines. I'm keeping that filter since I was born there, and my wife was born in 1982. 1982 xj650 Yay! I bought all my parts from NAPA locally.

I'm adding an in-line filter tomorrow. In addition, I'll be patching up the intake manifold/boots because they have small cracks in them. I'm just trying to buy some time until I have the boots here.

Does anybody know where to buy those carburator intake manifolds/boots? Thanks again Bigfitz!

Rod
Portland, OR

 

Hunt Flea-Bay or order new from Chacal for intake manifolds. They will set you back a bit but are worth the coin. That or fix your cracked units with black RTV and some bands cut out of an old bicycle inner tube.

 

I saw the parts from partsnmore.com but they're out of stock. Will continue to hunt. I drained the old fuel from the gas, and installed the in-line fuel filter today. I also managed to repair /bandage the crack boots. I can't wait to ride her again!

 

Parts-n-More tends to be hit or miss for parts (and customer relations as I've discovered). I can give Chacal a hearty endorsement as can most everyone on the forum. Good parts, knowledgable assistance and fast shipping. Glad to hear you are making progress.

 

Hey Copper, check out this thread for airbox boot alternative. I hate those suckers. Next time I mess with the carbs, this is the way I'm going to go.

http://www.xjbikes.com/Forums/viewtopic/t=18757/highlight=cheap+boots.html

 

Awesome! Thanks Jason. Did you ever tried this? just curious.