caliper rebuild

Greetings, all,

I've noticed a leaky caliper on my bike and have to rebuild them both. I've never done much brake work besides changing pads on my car. Could someone either give me or direct me to a step by step for getting the calipers off, the pistons out and putting it all back together?

Note: I don't have much in the way of facilities, so I don't have an air compressor with which to extract the pistons. I've read it can be done just using the pressure in the brake system on the bike. But if someone could break down how that works for me, I'd appreciate it.

Thanks.

 

I take it you havn't got a manual.
If you remove the pads, then pump the lever it should push out the piston, make sure you don't let the fluid get low in the M/C, I.ve never done it this way myself for fear of getting fluid on the paintwork, my boots etc, cover everything with plastic sheet.

 

have water handy. as brake fluid is water soluable. meaning water mixes real good and deactifies the disastrous chemicals in brake fluid.

 

oh you poor thing, i highly recomend finding a buddy or making new friends that have access to shop air. it so much easier and cleaner this way.

 

and to answer your question! i like to separate the two halves and then brake clean everything except the rubber covers, they dont like the chemical very well. its not the end of the world if they get soaked but be careful.then clean the piston and remove the two rubber rings in the piston bore, one of them actually retracts the piston after you release the brake lever. it also acts as the seal. the other one is a dust seal. just inspect the piston for damage and install the new seals after applying some brake fluid to lube them up really good. then add brake fluid to the piston and install, just be very careful instalin the piston it must go in straght or you will damage yoru new seals. then grease the slides where the two halves meet

 

Since your life depends on how well your Front Brake System operates; doing a complete overhaul and having the Front Binders perform well is something everyone should do.

The Piston can be pushed-out of the Caliper with a Grease Gun.

The Caliper's main seal is seated in a Channel.
That Channel should be spotlessly clean for best performance.

Chuck the Pad Retaining Pins into an Electric Drill and use Finishing Papers to apply the smoothest surface you can "Machine" (400/800/1000/1200)

http://www.yamaha-motor.com/sport/parts/home.aspx

Do yourself a huge favor and and acquire a Service Manual.

 

You definitely need a service manual.

You can get a basic idea of what's involved with a peek in the parts fiche: http://xjbikes.com/Forums/viewtopic/p=2 ... tml#246068 but it only really tells half the story.