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Front brake piston stuck in the "out" position, wont go back

Discussion in 'XJ Technical Chat' started by barberjw, Mar 23, 2012.

  1. barberjw

    barberjw New Member

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    Hey everyone. I managed to fix my carb/valve sync problem and now have another.
    While changing the front brake pads I undoubtedly did something wrong and now the piston is stuck in the "out" position and I cannot fit the new pads back in. I ride an 82 Maxim 650...at the moment with no front brake because its my only means of transport.
    Any idea how to get the piston back far enough to get the new pads back in?
    Thanks so much.
    John
     
    barberjw, Mar 23, 2012
    #1
  2. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    Did you rebuild the caliper/replace the caliper seals?
     
    bigfitz52, Mar 23, 2012
    #2
  3. Timmay

    Timmay Member

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    Is your piston dirty/pitted in any way? I suggest you take it out completely, clean the inside thoroughly, use a hone or elbow grease and smooth the walls where the piston goes, and the outside of the piston itself. I used 400 grit on the wall and 600 grit on the piston, nice and smooth. New seals from Chacal (click the animated banner at the top-left of this website)

    The piston should be shiny, polished, no dirt or rust.

    Replace seals if you have not done so, or if they are warped/enlarged.

    The piston should pop back in with minimal pressure (do NOT have your brake lines attached at all!) I used a ratcheting clamp to coerce mine.
     
    Timmay, Mar 24, 2012
    #3

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