HELP!! Brake caliper rebuild!

[fenix0069]

Does anyone know how to rebuild the front brake calipers on a 250r. My pistons are locked up inside and I haven't the slightest idea how to take the d*** things apart!

[Mxbubs]

Carencro? Ill be at Breaux Bridge Sunday if it doesnt rain.


Calipers? Cant be too hard.

[fenix0069]

at the drag track?

Yah the calipers are pretty tough. I can rebuild pretty much anything else on the bike but I havent figured those out yet.

are the lines still hooked up..if so pull the lever and see if the pistons move..if not heat up the caliper alittle

[fenix0069]

No the pistons dont move, the pistons are stuck inside for some reason.......right now i've got the calipers off the bike and the pads are out......thats where i got stuck.

[Mxbubs]

Since they are broke, want to sell them cheap?:D

The Mx track

are the pistons presed all the way in like they would be when replacing pads. if not try c-clamping them and see if you can get them to colapse in

are you trying to remove pistons?

i hope he was..that is what i thoughthe was taliking about

[fenix0069]

yah im trying to get the pistons out so i can see what is damaged and replace the piston and dust seals. The pistons are pressed all the way in.

hmmmm?your goning to have to build some preasure or something some how to get them out. plus dual pistons one will probably pop out and the other won't..i can't think of anything to help so good luck.

he is correct
but you can do it
i pm'd ya ...you got msn?

[fenix0069]

Thats awrite fellows i'll think of sumthing

heat them up with a torch if you can . if that don't work.. i dunno

do not heat em up
I can expalin ..read your pm ..
hit me on msn

[CHAR250R]

Hook the calipers back up to the lines. Don't put the pads back. Don't put the caliper back on the knuckle. Put a large C clamp on both calipers so the piston can't come out. If the pistons are out a little, gently compress the C clamp until the pistons bottom out. Bleed the front brakes. Remove the C clamp. Pump up the front brakes by using the brake lever. This should push out the piston on one or both of the calipers. If only one side comes out, you need to remove that caliper and plug that line up with a cap. Put the C clamp back on the caliper that still has the piston stuck in it, and bleed it. If you don't have the other line plugged up on the side without the caliper, you won't be able to bleed the stuck side. After you bleed the remaining stuck side, remove the C clamp and pump up the front brakes until the piston pops out. Put a rag over the calipers so you don't get a brake fluid bath. Put a pan under the calipers so you don't get brake fluid all over the floor. When yo get them completely apart, make sure you do a VERY good job of cleaning them. Check for corrosion and scratches. Scotchbrite and water works good. Dry them off comepletly. Reassemble with all new seals and you should be good to go. The manual says you can remove the piston by blowing compressed air into the inlet hole for the brake line. Your pistons are frozen, this may not work. Take your time and do a good job, it will be worth it. Let me know how you make out. Charlie.

this is good instructions
..a way to avoid having to work with 2 at same time is to put front caliper on rear line(provided you want or have the rear off too ,good idea to rebuild all at same time ) ...this is easier to work with ..while getting pistons to move in order to rebuild &
& much quicker to bleed 1 then 2 ..

[CHAR250R]

Good idea. Didn't think of putting it on the back. You'll need 6 crush washers instead of 4 if you go that route.

[fenix0069]

sounds like a good idea....thanks i'll do it as soon as i get home!

;)

[fenix0069]

Thanks fellas it worked great!