Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech
getting the second brake piston out? getting the second brake piston out?
Register FAQ Calendar Today's Posts
Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Photo by Ellen Delis, Lagunas Ojos del Campo, Antofalla, Catamarca

I haven't been everywhere...
but it's on my list!


Photo by Ellen Delis,
Lagunas Ojos del Campo,
Antofalla, Catamarca



Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 19 Mar 2008
Contributing Member
Veteran HUBBer
  
Join Date: Jan 2006
Location: Sheffield
Posts: 994
getting the second brake piston out?
dear all

After much fiddling and splilt brake fluid I have finally got the pistons out of my FZR calipers. Well I got one piston out of each..... how do I get the second one out without a compressor?? I got the first ones out by pumping them out with a spare front brake master cylinder. I could replace one side and then do the other by holding the first in with a clamp, but would rather get them both out so I know the caliper is spotlessly clean for a rebuild - any suggestions anyone?
Reply With Quote
  #2  
Old 19 Mar 2008
mattcbf600's Avatar
Gold Member
Veteran HUBBer
  
Join Date: Aug 2006
Location: London, England
Posts: 706
Quote:
Originally Posted by henryuk View Post
dear all

After much fiddling and splilt brake fluid I have finally got the pistons out of my FZR calipers. Well I got one piston out of each..... how do I get the second one out without a compressor?? I got the first ones out by pumping them out with a spare front brake master cylinder. I could replace one side and then do the other by holding the first in with a clamp, but would rather get them both out so I know the caliper is spotlessly clean for a rebuild - any suggestions anyone?
A neat little trick is to use tyre irons - or something similar.

Place a bar between the irons

|o|

then insert the irons into the cylinder

|o|
\ /
|_|

Squeeze the top so that pressure is exerted inside the cylinder and then pull.

Get plenty of penetrating oil in there first. Works quite well if you're without a compressor.

Hope that helps.

m
__________________
------------------
http://thelondonbiker.com/blog

Watch some of my camp cooking videos

AIM: mattcashmore
SKYPE: matthewcashmore
MSN: matthew@matthewcashmore.com
Reply With Quote
  #3  
Old 19 Mar 2008
Robbert's Avatar
Contributing Member
Veteran HUBBer
  
Join Date: Sep 2001
Location: Gent, Belgium
Posts: 523
I always push one almost out, just a few mm's in the caliper. Then clamp it and push the otherone out. The last mm's of the first piston I can get it out by hand.

rob
Reply With Quote
  #4  
Old 19 Mar 2008
Contributing Member
Veteran HUBBer
  
Join Date: Jan 2006
Location: Sheffield
Posts: 994
cheers
thanks for the tips, will dig those tyre irons out and give it a whirl...
Reply With Quote
  #5  
Old 23 Mar 2008
Registered Users
HUBB regular
  
Join Date: Sep 2007
Location: Edinburgh
Posts: 33
I just had the same fight with 2 really old front calipers from an xtz 750. All four pistons were very much seized in place.

My recipe for removal was.

1.wait till the wifes out of the house for a few hours.

2. preheat oven to 180C

3. find an old oven tray

4. place afor mentioned caliper's onto tray

5. bake for 4 mins

6. remove from oven and free the pistons using vice grips.

I was renewing all the internals of the caliper's so wasnt to concerned about gouging/scratching the pistons or the fact that 2 seals melted.

Took minutes to remove once out of the oven. The previouse day I'd used about an hours worth of foul lanuage and shouting to no avail.

I've just cooked the sunday roast in the same oven. If i dont post again soon then you'll know It's a bad idea and may poison you..

Good luck.
Reply With Quote
  #6  
Old 31 Mar 2008
bacardi23's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Sep 2007
Location: XXX<-Portugal->Azores->Santa Maria (island)
Posts: 1,544
Get yourself a DOT3 or DOT4 brake fluid bottle whichever is the one for your brakes.....take the bleed screw out and when you compress the pistons some oil should come out or just unscrew the brake cables.... that should work....
Reply With Quote
  #7  
Old 31 Mar 2008
Contributing Member
Veteran HUBBer
  
Join Date: Feb 2004
Location: Edinburgh
Posts: 762
the tyre-lever method works well. I use metal bicycle tyre levers, which seem to be the perfect size. but if you are still struggling, take the caliper to your friendliest bike shop, they'll have a very useful little tool that extracts the little gits out with no fuss/force.
Reply With Quote
  #8  
Old 31 Mar 2008
Contributing Member
Veteran HUBBer
  
Join Date: Jan 2006
Location: Sheffield
Posts: 994
Couldn't get the tyre levers out, so ended up taking one out, cleaning, putting old seals and piston back in, take other one out, clean, put new seals and piston in, clamp and replace 1st piston. Bit of a ballache - do the brake piston removing tools (such as the one by Sealey) work then Dougie? I will have to do this quite a lot so might invest in one!
Reply With Quote
  #9  
Old 7 Apr 2008
Contributing Member
Veteran HUBBer
  
Join Date: Feb 2004
Location: Edinburgh
Posts: 762
hi,

yes, the piston removers do work. not sure about the Sealey one (only because I haven't seen it). I tend to end up with Kawasaki's which need a lot of brake caliper attention. So I'm thinking of getting one. When I get round to it I'm going to ask my local bike shop which brand they use.

cheers,
Doug
Reply With Quote
  #10  
Old 7 Apr 2008
Contributing Member
Veteran HUBBer
  
Join Date: Jan 2006
Location: Sheffield
Posts: 994
Dougie

let me know what the good stuff is! Have just gone through the manual for my latest project and it suggested splitting the caliper to overhaul the brake piston seals - sounds a bit off to me.... anyone split their calipers?
Reply With Quote
  #11  
Old 7 Apr 2008
Contributing Member
Veteran HUBBer
  
Join Date: Feb 2004
Location: Edinburgh
Posts: 762
hmm... depends on your calipers. the last few I've done have been six-pistong tokico. and I normally gently push the pistons out with the caliper whole, so the pistons meet in the middle. Then split the caliper and pull the pistons out.

Not sure I understand how you'd get the piston out without splitting the caliper? I'm assuming an active piston either side of the caliper. I think an old GT550 caliper I once serviced only had a single active piston, and was a single cast item.

what's the Sealey tool, do you have a link?
Reply With Quote
Reply

« Previous Thread | Next Thread »

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
Help XT600E big bore piston kit bacardi23 Yamaha Tech 27 21 Jun 2016 23:30
question about piston zonkface Yamaha Tech 3 8 Nov 2006 08:15
piston rings, which way up? big t Yamaha Tech 9 31 May 2006 21:47
BMW GS brake upgrade - 4 and 6 piston etc Grant Johnson BMW Tech 3 10 May 2004 15:29
brake piston bigbrummer Yamaha Tech 0 1 Apr 2004 23:09

 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now, and add your information if we didn't find you.

Next HU Eventscalendar

HU Event and other updates on the HUBB Forum "Traveller's Advisories" thread.
ALL Dates subject to change.

2024:

Add yourself to the Updates List for each event!

Questions about an event? Ask here

HUBBUK: info

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

Your ad could be here, on EVERY page of the HUBB, or the whole website, or as many as you like!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.



All times are GMT +1. The time now is 13:16.

Contact Us - Horizons Unlimited Motorcycle Travellers Website - Archive - Privacy Statement - Top