View Full Version : Brake Overhaul - picture heavy
Al_Sweetman
25-02-09, 09:46 PM
OK,
As promised I'm uploading piccies of my brake overhall.
This is day one - showing (brief) pics of what it looks like before, finishing with the end-of-day-1 results...
Calipers before start
http://farm4.static.flickr.com/3454/3309353349_728c515ffc_d.jpg
The spring is meant to be silver!
http://farm4.static.flickr.com/3603/3309352785_52766ffb69_d.jpg
Pistons (one clean-ish)
http://farm4.static.flickr.com/3302/3309353951_25b05b7687_d.jpg
Results after day one - lots of autosol, brake cleaner and hard work.
http://farm4.static.flickr.com/3329/3310183780_cebafff38e_d.jpg
http://farm4.static.flickr.com/3556/3309354633_cbc37b06cd_d.jpg
Getting there slowly!
Tomorrow brings sorting out the inside of the piston chamber, and fitting new seals etc.
Dave20046
25-02-09, 09:48 PM
Any instructions? Or explanation on what you did matey? I need to clean mine up but wouldn't mind knowing the best course of action. Do the pistons just come out with no messing? And go back in straight forward enough? Have you felt an improvement?
(I intend to do it with them still on the bike)
Al_Sweetman
25-02-09, 09:55 PM
Will be coming along soon - writing down what I've done so far outside of t'internet... That way I won't lose it when my connection goes!
Quick responses:
> Any instructions?
> Or explanation on what you did matey?
Coming :-)
> Do the pistons just come out with no messing?
All depends... mine didn't!! Had to get them most of the way out and then used thin bit of rubber (heatshrinking I think) to protect the pistons while I pulled the buggers out with some pliers.
> And go back in straight forward enough? Have you felt an improvement?
That is the million dollar question I hope to find out by this weekend! Put it this way, when I took them apart, the pads weren't sliding at all, and at least one was seized...
yorkie_chris
25-02-09, 10:29 PM
Suzuki kindly provide a hydraulic brake piston removing tool on the bike as standard.
Loving the glass of wine.... lol
clean pistons you have there...
pencil shavings
25-02-09, 11:19 PM
Suzuki kindly provide a hydraulic brake piston removing tool on the bike as standard.
:razz:
ThEGr33k
25-02-09, 11:31 PM
Ill probably have to do this at some point too :( Not that they feel bad, quite the opposite. :D
Dave20046
26-02-09, 08:03 AM
Suzuki kindly provide a hydraulic brake piston removing tool on the bike as standard.
That's fecking generous of them...unfortunately I didn't get the tool kit with my bike, previous owner lost it :(
:rolleyes:
breakz187
26-02-09, 11:31 AM
Pump them out with the brake lever!
Al_Sweetman
26-02-09, 11:35 AM
Suzuki kindly provide a hydraulic brake piston removing tool on the bike as standard.
:rolleyes: tee hee!
Pump them out with the brake lever!
In principal, yes... but be warned (as I found to my detriment) it's more than likely that one piston will be all to happy to pop out, and will do so before the other one can, meaning that as you're pumping on the brake there's suddenly a pop and a squirt and all the brake fluid that was behind the (now extracted) piston goes everywhere, and you have to resort to pliers to remove the other half-in, half-out piston :smt010
Dave20046
26-02-09, 11:38 AM
:rolleyes: tee hee!
In principal, yes... but be warned (as I found to my detriment) it's more than likely that one piston will be all to happy to pop out, and will do so before the other one can, meaning that as you're pumping on the brake there's suddenly a pop and a squirt and all the brake fluid that was behind the (now extracted) piston goes everywhere, and you have to resort to pliers to remove the other half-in, half-out piston :smt010
(sorry for my ignorance I've never stripped breaks before) behind the pistons is it just fluid? So if you remove the pistons all your fluid will drain? or is there a seal in there so only a bit of fluid is behind the pistons :confused:
breakz187
26-02-09, 11:39 AM
ok, dont do that, and i wont be doing that on my brake overhaul in the next few weeks :)
Al_Sweetman
26-02-09, 11:43 AM
(sorry for my ignorance I've never stripped breaks before) behind the pistons is it just fluid? So if you remove the pistons all your fluid will drain? or is there a seal in there so only a bit of fluid is behind the pistons :confused:
Don't see it as ignorance, fear not!!
Dunno if you can see it from the pics, but the pistons are like an egg cup - the outside of which fits in the calliper 'hole' -> behind this is a small wee hole that the brake fluid gets pumped into and, in doing so, causes the pistons to 'push' the pads onto the disc (they're trying to pop themselves out, essentially). That's what the seals are for - they stop the brake fluid getting out around the pistons and onto the pads, and any s**t getting from the outside (pads) into the piston 'chamber'/sides... As it's a vacuum (?correct or not?) when the brake is released, the fluid gets sucked back up the pipe (a little bit) and the pistons are pulled back in, thus pulling the pads from the disc.
In answer to your question, if you remove the pistons then yup, all your fluid will drain out (if you pump it). That's a caveat (please tell me if I'm wrong!) - only if you pump. As it's a "closed" system, the fluid will only vcome out if you pump it. Otherwise, if you manage to get the pistons out with some fluid still left in the system, it shouldn't **** out afterwards.
Dave20046
26-02-09, 11:48 AM
Don't see it as ignorance, fear not!!
Dunno if you can see it from the pics, but the pistons are like an egg cup - the outside of which fits in the calliper 'hole' -> behind this is a small wee hole that the brake fluid gets pumped into and, in doing so, causes the pistons to 'push' the pads onto the disc (they're trying to pop themselves out, essentially). That's what the seals are for - they stop the brake fluid getting out around the pistons and onto the pads, and any s**t getting from the outside (pads) into the piston 'chamber'/sides... As it's a vacuum (?correct or not?) when the brake is released, the fluid gets sucked back up the pipe (a little bit) and the pistons are pulled back in, thus pulling the pads from the disc.
In answer to your question, if you remove the pistons then yup, all your fluid will drain out (if you pump it). That's a caveat (please tell me if I'm wrong!) - only if you pump. As it's a "closed" system, the fluid will only vcome out if you pump it. Otherwise, if you manage to get the pistons out with some fluid still left in the system, it shouldn't **** out afterwards.
Ahh cheers, right in that case I'll have a bucket near by pop out the pistons give em a clean and check the seals (won't know what I'm looking at tbh) thenput it back together and top up and bleed the system a bit.
I'll be joining the brake overhaul club! if I can only get the damn rear brake off! :smt074
silly question, is it necessary to drain the system to take the caliper off? will the system hole in the juice?
ah, just found my answer!
:stupid:
yorkie_chris
26-02-09, 01:35 PM
Yes the fluid will drain out. It is not closed system, there is a transfer port in the master cyl.
Al_Sweetman
26-02-09, 01:53 PM
If YC says it's so, I'd believe him!
Bit confused though, as in my ignorance I thought that if the 'cap' wasn't off the 'brake fluid holder' there'd be no way for the fluid to come out - a bit like when you stick your thumb over the top of a straw and pull it out of the liquid - it gets stuck inside...
Bit confused though, as in my ignorance I thought that if the 'cap' wasn't off the 'brake fluid holder' there'd be no way for the fluid to come out - a bit like when you stick your thumb over the top of a straw and pull it out of the liquid - it gets stuck inside...
Air will be able to get up the lines, therefore allowing fluid out. There's usually a small air gap in the res.
Al_Sweetman
26-02-09, 02:02 PM
Makes sense - cheers.
Ignorance is bliss until you get rudely awoken :-D
yorkie_chris
26-02-09, 02:03 PM
Nah the reservoir is kinda sealed, but the membrane on top of it allows a change in volume.
so drain the system first, then take brake off to clean, replace brake, refill system, got you \\:D/
punyXpress
26-02-09, 02:18 PM
What's behind the pistons will flood out, & that in the pipes will trickle out unless you pull the lever.
How do I know?
It's an age thing, so guess which I am.
yorkie_chris
26-02-09, 02:18 PM
No, pump pistons out, will get rid of most of the old fluid, then remove caliper. Catch the old stuff in a tin or with rags or something.
yorkie_chris
26-02-09, 02:18 PM
What's behind the pistons will flood out, & that in the pipes will trickle out unless you pull the lever.
How do I know?
It's an age thing, so guess which I am.
Indeed that will close transfer port and stop you losing fluid out of the reservoir.
punyXpress
26-02-09, 02:20 PM
If one piston is nearly out & the other hasn't moved, hold the moving one with a narrow G clamp so the other is forced out.
I've done this on several different bikes, good job to do, time comsuming but very rewarding…
tip..
hold one piston down with a clamp, pump the brake, let the other piston come out a bit (halfway), hold it with a clamp, release the other piston from clamp, pump the brakes till the piston comes out… then your other piston will be halfway out and easier to get out…
what I do is clean one by one though….but I take the caliper completely off the bike and use an air compressor to pop the pistons out, clamp x number of pistons down (will depend on bike) and put air in to pop the free one out..clean, replace seals, put back in…
then repeat this for the other pistons
Also by using this method of not allowing the piston to come out completely, you can clean the pistons a bit, using a tooth brush.
this helps to get rid of some of the road muc and release the pistons a bit…
(in case you can't be bothered to go through all the replacing seals, new fluid in, bleeding brakes stuff….)
Al_Sweetman
26-02-09, 02:31 PM
Indeed that will close transfer port and stop you losing fluid out of the reservoir.
So I was right the first time around?
Aw man my head hurts now.
Dave20046
27-02-09, 08:17 AM
Just to clarify what's the quickest easiest way to efectively clean up the brakes without faffing around draining the system?
Is there one.
timwilky
27-02-09, 09:12 AM
why are people so worried about draining the system. You need to change your fluid every couple of years, it is cheap, what is the problem?.
Brakes are what keep you alive, the fluid is an important part of the brake system, don't compromise. Do the job properly.
Use the on board extraction tool, as the pistons get pumped, a small g clamp to stop them popping until all are pushed out and then remove clamps, remove pistons, give them a polish. remove old seals, clean out the calipers properly, do not score anything, reassemble with a bit of red rubber grease on the new seals.
New fluid, bleed, and enjoy
Dave20046
27-02-09, 09:15 AM
why are people so worried about draining the system. You need to change your fluid every couple of years, it is cheap, what is the problem?.
Brakes are what keep you alive, the fluid is an important part of the brake system, don't compromise. Do the job properly.
Fine lol I was just going to bleed the system/ but how hard is it to drain and refil the system?
reassemble with a bit of red rubber grease on the new seals.
what is red rubber grease? what's it's purpose on a bike :confused:
cheers :D
maviczap
27-02-09, 09:27 AM
what is red rubber grease? what's it's purpose on a bike :confused:
cheers :D
It's specifically designed for use with rubber seals, keeps them and the pistons lubricated. Stops them drying out and perishing. Stops road muc geeting where it shouldn't
Got some from Wemoto this week, wiv some other bits and bobs
Dave20046
27-02-09, 09:46 AM
Andyone in the sheffield area have a dab I could borrow?
It's specifically designed for use with rubber seals, keeps them and the pistons lubricated. Stops them drying out and perishing. Stops road muc geeting where it shouldn't
Got some from Wemoto this week, wiv some other bits and bobs
Can it be used on other rubber bits? apart from the tyres :rolleyes:
Al_Sweetman
27-02-09, 10:27 AM
Hey guys,
Sorry for the quietness yesterday - was removing the lines and continuing the cleaning.
Managed to source some rubber grease - popped to the local (of all places, Triumph!) shop - they've just taken over our Suzuki stealership, and asked the bloke very nicely if I stuck him a £5 would he fill my little pot with rubber grease? He actually said "keep the £5 and take these sachets!" - top decent chap, that guy.
So - tonight will be assembling, bleeding and testing.
Updates to follow!
Luckypants
27-02-09, 10:36 AM
Got some from Wemoto this week, wiv some other bits and bobs
You did? I could not find it on their website, how did you find it? I got mine from the MG owners club! (not a member)
maviczap
27-02-09, 10:44 AM
Can it be used on other rubber bits? apart from the tyres :rolleyes:
Yes, i should think that your blow up friend would appreciate a little extra lubrication :safe:
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