Front Brake Caliper Re-assembly, help! (1982 MAXIM 650)

Thanks in advance, this forum is the best!
I got this caliper in a bag with loose parts, I was missing this part so i ordered it, now that I have it Im not sure how its supposed to fit in. Any help/tips would be greatly appreciated! If anybody has a picture of a assembled or attached caliper that'd be awsome

 

Does this help?

You find this drawing here:

http://www.yamahapubs.com/index.do

 

Thanks so much, thats a great help! Unfortunately, im missing the yellow part, which sucks! Anybody know what part/number that is?

 

My XJ650J didn't have the yellow part either. Never seemed to be a problem. It doesn't have a part number so if it ever existed it was part of the caliper assembly and not a separate item.

Interestingly I was working on a 1980 XS850 special today. It didn't have the yellow part although the caliper is similar. I just checked the fiche, caliper has the same part number but the drawing does not include the yellow part.

Your shiny new part actually goes onto the fork leg. The tabs on the pads go into it.

 

just worked on mine. don't know what that yellow part is. i don't have it either.

as for making it fit. you have to compress the caliper back inside. a good c clamp does the job. unless you have some big channel lock pliers. hopefully the caliper isn't froze or offers any resistance.

 

Just checked service manual - yellow part not there either.

Must be an error in the fiche......

 

I have no idea how to get this caliper back on! I cant get the rotor to fit in between the brake pads, is it that the piston is froze in an extended position? What do I Do to fix this? Am I missing a rubber seal on my piston? (picture above) Or are those parts internal? Thanks again!

 

You have to retract the piston all the way back into the caliper. You will need a C-clamp for that. Most auto parts stores will let you borrow one.

 

Thanks! I finaly got my caliper cleaned out and ready to go. I can get it in with the old worn pads on, but im totally clueless on how to clamp the piston in and put the caliper on with new pads. Could anyone give me some guidance/instructions/pictures on how to do this? Thanks so much for all the great advice,
DG

 

Ooooo... I don't have that metal part on mine nor the yellow part either.

Hmmm...

 

i was able to get the caliper on with the eold pads, i just dont know how to compress the piston to get it on with new pads. It doesnt seem like that yellow part is needed

 

There's plenty of tricks for Compressing the Caliper Piston to install New Pads.

Crack-open the Bleed Screw and Lever the Piston back into the Caliper ... protecting the Brake Rotor with a thin, strip of Vinyl Siding.

Remove the Caliper and Put a Socket with a Quarter taped over the 3/8th's square on the Socket ... then, use a C-Clamp to Press the Piston all the way back-in.
Once again, cracking the Bleeder will relieve Hydraulic Pressure and make the job much easier.

(( Glue a Patch of Bicycle Inner Tube on the C-Clamp to prevent marring the Caliper. ))

 

Thanks! So when you compress the piston in with a c-clamp, does the piston stay retracted so you can then take the c-clamp off and put the new pads in/re-install the caliper over the rotor?

 

If you crack a Bleeder and push the Caliper Piston back into the Caliper it will stay-put and let you install the New Pads.

Once the Piston is moved back ... close the Bleeder of Fluid or Air could be introduced to the System.

After you install the New Pads ... Pump the Brake Lever for a moment to build-up the pressure and move the New Pads out to where they belong.

Glance at the Master Cylinder Sight Glass.
Top-off the MC if need be.

 

thanks, i got the piston compressed. One last thing, im not sure how the bolt and washers are arranged where the caliper bolts on to the fork leg. I cant tell whats what in the schematic. the bolt comes in from the bottom of the caliper, goes through the throttle sleeve, gets tightened into the fork leg, and a washer and nut goes on top. What im not sure about is if a washer goes between the top of the caliper and the bottom of the fork leg? Or if a washer goes on the bottom of the caliper where the botl enters? If so , which one? Thanks!

 

put the bolt through the hole. put the big washer on first. little washer next. then the nut.

 

thanks, does the big and little washer both go on the top, below the nut? does anything go between the caliper and fork leg?

 

Here's the Diagram.

While you have the Sleeve out ...
Clean the Caliper Bore where this Sleeve gets placed.
Use a Bore Cleaning Brush or twist ScotchBrite through the Bore.

"Shine" the Outside Diameter of the Sleeve free from all corrosion and oxidation.
Push wads of Steel Wool through the Inside Diameter of the Sleeve until you can look into the Sleeve and see that the Inside Diameter is CLEAN!

Visit a Hardware Store.
Replace:
Bolt
Flat Washers
Nut
(Hardened Hardware / Metric

 

Thanks for the advice! Il definitly clean that out and replace the parts as suggested. I didnt see the diagram in the post, Right now this is how i have the washers etc arranged, is this right?

 

also, your supposed to use locktitie to secure the bolt,right? But how will I take the caliper off later?

 

The Loctite will allow you to disassemble later.

The Loctite prevents the parts from coming loose.

 

Thanks! Should i put the locktite on the top nut? Or do i put it on the bolt before i screw it intp the fork aswell?
DG

 

Put it on the Threads of the Bolt.

Then, you'll have it where the Nut end-up tight.

 

Thanks! Sorry to kee p asking questions, but do you put the locktite on the thread of the bolt before you screw it into the fork leg? Or do you just put it on teh thread of the top part of the bolt where the top nut goes on?