I think it was the aluminium going off (oxidised?) area under each dust seal, in the groove, was the same on each pot. I woz lucky enough to have a VTR with PFM six pots and iron discs a while back. The calipers were a work of art, all surfaces hard anodised, fasteners and pins all stainless and get this, teflon coated pistons!

Re: Front calipers seized
 

Sorry to bring this up again, but how did you get your seized brake pins out? I've tried everything, including soaking in penetrative oil overnight, tapping with hammer, heating up with boiling water. I rounded off the bolt at the end straight away using brand new tools and not one of the 3 people that had a go can move it even with mole grips so tight the bolt is squashed..

I know there are solutions like cutting the pin out or drilling from the other side but I'd prefer to do something less drastic if I can. Failing all of this, how much does it usually cost for a garage to do it :/

Re: Front calipers seized
 

Currently having the same problem as above any one get any ideas?

Re: Front calipers seized
 

Grind off the lump on the other side and tap it out from there. That's the easiest way, use copper grease on the pin when you put it back, then put a blob of normal grease in the cavity when it's all back together.

Putting the seals and pistons back with rubber grease is the only way to keep them moving.

I'm quite impressed with the brembos on MissYC's cagiva planet, that was sat uncovered outside for 3 years or so, all the pistons shifted with only air pressure. The calipers are coated (anodised perhaps?) and the pistons teflon coated, all the steel bits were rusted but the working parts were fine.

Re: Front calipers seized
 

I received a spare set of calliper when i bought my bike that were taken from a crashed 04/05 bike I believe. I am going to try and fit those to remove the bugeration factor.

Thanks for the advise Chris!

Re: Front calipers seized
 

Grinding off the lump sounds good Chris but I'm wary of damaging the calipers (perhaps drilling would be better as I dont have a grinder). I finally have a new brake pin and paperclip style pin to replace the old one and would love to be able to do this without draining the brake fluid (i have some just in case).

Is there any way to finally get this sorted without taking the caliper off the bike?

Re: Front calipers seized
 

You're best to take the caliper off as you risk damaging hoses etc trying to work on it on the bike. Renewing your brake fluid is never a bad idea anyway.

You could file the lump off once the caliper is off and then tap it through or drill it out from there like i had to do as that baby was not budging!

Re: Front calipers seized
 

Yes filing it off is fine. You won't get it out any other way really. It's not damaging the caliper, it's modifying.

Re: Front calipers seized
 

Also before you put the new pad retaining pin in file some flats on it so that it is less likely to seize the next time around. And plenty of grease too.

Re: Front calipers seized
 

Thanks for the tips guys, I'll have a go this weekend and let you know if I got it out. By filing flats do you mean filing the end so it is slightly square and there is a gap between edges of pin and surrounding metal?