Brake rebuild

Tech section strictly for the FJR. Everything from oil changes & suspension setup's to removing sheep hair from hard to reach places on the bike so that your wife never finds out.
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Canadian FJR
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Brake rebuild

Post by Canadian FJR »

I would have thought that you could pop the pistons out. First time I saw the blue cap removed.

https://m.youtube.com/watch?v=3EURdRwxj4w



Canadian FJR
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raYzerman
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Re: Brake rebuild

Post by raYzerman »

I didn't watch the whole thing but those blue cap ones are like the Gen1's... I didn't like he grabbed the pistons with needle nose pliers... there are piston removal tools that expand inside the pistons so you can twist/turn/pull them out. A band clamp type can be used on the OD's, but be careful not to score the piston where it will be in contact with the seal.

I usually take a well worn set of brake pads and insert them while the caliper is still on the bike.... do this to all calipers while they're on the bike if you're going to rebuild them all.... pump up the brakes until the pistons all move out to squeeze those worn out pads... remove the pads now, and the pistons are almost all the way out.... easier.

I tend not to use brake cleaner spray on pistons because some of them can harden the seals. I clean them with a toothbrush and brake fluid, rinse with isopropanol....
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Powerman
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Re: Brake rebuild

Post by Powerman »

Yeah those pliers scared me too, just asking for a leak.

On gen two I put a block of wood between two pistons, clamp the third, and shoot the forth piston out with brake fluid pressure. I replaced the seals, one bore at a time. My fluid is kept pretty clean. I try not to separate the halves.
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FJRoss
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Re: Brake rebuild

Post by FJRoss »

Canadian FJR wrote: Sat Nov 20, 2021 1:19 pm I would have thought that you could pop the pistons out. First time I saw the blue cap removed.

https://m.youtube.com/watch?v=3EURdRwxj4w



Canadian FJR
Problem with brakes on the '03 or just preventative maintenance after 18 years?
I never had to do anything (including seals) on my '07 although the outer parts on a couple of the pistons were a bit pitted. Never caused any leakage because the rough bits were outside the seals. Might have become an issue in another few years?

What are you replacing - just seals?
Canadian FJR
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Joined: Mon Sep 01, 2014 8:31 am
FJRModel: 2018 FJR-1300ES, 2010 Ural Gear Up, 2003
Yamaha FJR-1300, 2001 Kawasaki KLR-650 (Gone to a new home), 1997 Suzuki TL-1000s (Gone but not forgotten), 1976 Honda 400 Four, 1968 Honda C-50 Step-thru
Location: Nova Scotia, Canada
x 24
x 318

Re: Brake rebuild

Post by Canadian FJR »

Not replacing anything, just cleaned pistons and fresh fluid. I do this every winter.

Stumbled on this video while looking for something else.

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Re: Brake rebuild

Post by FJRoss »

Canadian FJR wrote: Sat Nov 20, 2021 10:13 pm Not replacing anything, just cleaned pistons and fresh fluid. I do this every winter.

Stumbled on this video while looking for something else.

Canadian FJR
Makes sense. I usually flush hydraulics annually as well. I clean pistons whenever I change pads or swap them around to even out wear. I just extend the pistons to clean them - I don't pop them out.
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