Pumping 4 Pot Calipers (SV/GSXR Brake Swap) - SV650.org

squirrel_hunter · 26-04-07, 10:34 PM

I have a set of 4 pot calipers and they need the pistons pumping out and cleaning. Unfortunately they are a bit seized and a bit dirty.

Having only worked with 1 and 2 pot calipers whats the best way for me to do this?

If I pump them as is the pistons will meet in the middle. I don't want to tap them back into the caliper as they are covered in crud and the only way to clean them properly is removal.

But before anyone says compressed air, I don't have a compressor and I want to do this myself so I'm not going to be taking them to a shop.

I would prefer a non destructive method as although the pistons and seals will be replaced I would like to keep them marginally usable for test fitment.

Your thoughts please...

northwind · 26-04-07, 10:57 PM

I'd pump them out as far as they'll go- trying to keep them all equal, using gclamps and such- and then split the caliper and pull them the rest of the way out manually.

Well, that's a lie, I'd use compressed air

but if air was in short supply, that's what I'd do.

26-04-07, 11:15 PM

Quote:

Originally Posted by northwind

I'd pump them out as far as they'll go- trying to keep them all equal, using gclamps and such- and then split the caliper and pull them the rest of the way out manually.

Well, that's a lie, I'd use compressed air

but if air was in short supply, that's what I'd do.

Me too, failing that a brake piston removel tool will work

but not cheap

http://cgi.ebay.co.uk/MOTORCYCLE-BRA...mZ200078855141

Lissa · 27-04-07, 06:53 AM

Pump them out then make up a tool using 2 bits of threaded bar or bolts and a couple of pieces metal bar and expand it into the hollow part of each piston, and use this for leverage and turning. Maybe soak the calipers in oil overnight beforehand.

Haven't used this method, but sounds possible in theory.

Pete

Sid Squid · 27-04-07, 07:33 AM

Pump them as far as they'll go, split the calipers and they'll come out by hand when you rock them with your thumbs.

jambo · 27-04-07, 01:39 PM

Agree with above, if it's stiff as all hell drop the whole caliper in a bucket of hot water for 10 minutes then try again

27-04-07, 02:06 PM

Quote:

Originally Posted by Sid Squid

Pump them as far as they'll go, split the calipers and they'll come out by hand when you rock them with your thumbs.

True! Yesterday I've put new seals in my rear caliper and cleaned it. I did it this way and it worked. Although I had to use a vise-grip to pull a piston out, just make shure you don't damage the other of the piston by using a rag.

squirrel_hunter · 27-04-07, 10:40 PM

Well I had another go with one of the calipers tonight. And after pumping them as far as they will go and splitting the caliper I still can't get them out.

So I will try soaking them and will pop out to get some clamps tomorrow.

Unfortunately one of the pistons is now at a jaunty angle. Tried taping it straight with a rubber mallet, but no joy. So will try the other caliper and hopefully be able to swap the halfs over to get them out. But if this fails I'm going to need a sledge hammer.

I hate brakes. But this is all good practice at bleeding them I suppose.

26-04-07, 10:34 PM	#1
squirrel_hunter Member Mega Poster Join Date: Apr 2005 Location: Sunny Swindon Posts: 3,579	Pumping 4 Pot Calipers (SV/GSXR Brake Swap) I have a set of 4 pot calipers and they need the pistons pumping out and cleaning. Unfortunately they are a bit seized and a bit dirty. Having only worked with 1 and 2 pot calipers whats the best way for me to do this? If I pump them as is the pistons will meet in the middle. I don't want to tap them back into the caliper as they are covered in crud and the only way to clean them properly is removal. But before anyone says compressed air, I don't have a compressor and I want to do this myself so I'm not going to be taking them to a shop. I would prefer a non destructive method as although the pistons and seals will be replaced I would like to keep them marginally usable for test fitment. Your thoughts please... __________________ "A little enthusiastic?" May I add here, GG is awesome and I think I am in love with Stretchie...he rocks my world! SH2 \| 2MA \| GROM \| YSR

26-04-07, 10:57 PM	#2
northwind Moderator Mega Poster Join Date: Jan 2004 Location: In the garage where I belong Posts: 17,083	Re: Pumping 4 Pot Calipers (SV/GSXR Brake Swap) I'd pump them out as far as they'll go- trying to keep them all equal, using gclamps and such- and then split the caliper and pull them the rest of the way out manually. Well, that's a lie, I'd use compressed air but if air was in short supply, that's what I'd do. __________________ "We are the angry mob, we read the papers every day We like what we like, we hate what we hate But we're oh so easily swayed"

27-04-07, 06:53 AM	#4
Lissa Just Ballast Mega Poster Join Date: Feb 2006 Location: Rugby, South Mids Group Posts: 4,381	Re: Pumping 4 Pot Calipers (SV/GSXR Brake Swap) Pump them out then make up a tool using 2 bits of threaded bar or bolts and a couple of pieces metal bar and expand it into the hollow part of each piston, and use this for leverage and turning. Maybe soak the calipers in oil overnight beforehand. Haven't used this method, but sounds possible in theory. Pete __________________ If It's Too Loud, You're Too Old! I'd Rather Have Two Big Bangs Than Four Little Strokes

27-04-07, 07:33 AM	#5
Sid Squid No, I don't lend tools. Mega Poster Join Date: Jul 2003 Location: Skunk Works, Nth London Posts: 8,680	Re: Pumping 4 Pot Calipers (SV/GSXR Brake Swap) Pump them as far as they'll go, split the calipers and they'll come out by hand when you rock them with your thumbs. __________________ If an SV650 has a flat tyre in the forest and no-one is there to blow it up, how long will it be 'til someone posts that the reg/rec is duff and the world will end unless a CBR unit is fitted? A little bit of knowledge = a dangerous thing. "a deathless anthem of nuclear-strength romantic angst"

27-04-07, 01:39 PM	#6
jambo Member Mega Poster Join Date: Aug 2003 Location: Croydonia Posts: 5,376	Re: Pumping 4 Pot Calipers (SV/GSXR Brake Swap) Agree with above, if it's stiff as all hell drop the whole caliper in a bucket of hot water for 10 minutes then try again __________________ Modern motorcycles are bloody brilliant, enjoy it while we can

27-04-07, 10:40 PM	#8
squirrel_hunter Member Mega Poster Join Date: Apr 2005 Location: Sunny Swindon Posts: 3,579	Re: Pumping 4 Pot Calipers (SV/GSXR Brake Swap) Well I had another go with one of the calipers tonight. And after pumping them as far as they will go and splitting the caliper I still can't get them out. So I will try soaking them and will pop out to get some clamps tomorrow. Unfortunately one of the pistons is now at a jaunty angle. Tried taping it straight with a rubber mallet, but no joy. So will try the other caliper and hopefully be able to swap the halfs over to get them out. But if this fails I'm going to need a sledge hammer. I hate brakes. But this is all good practice at bleeding them I suppose. __________________ "A little enthusiastic?" May I add here, GG is awesome and I think I am in love with Stretchie...he rocks my world! SH2 \| 2MA \| GROM \| YSR

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