How are the calipers re-built?

[dna9656]

Any instructions on how to re-build the (front and rear) calipers on my XVZ12DKC2?

I just found plenty here on the forum about this but any additional advise would be appreciated.

Edited March 13, 2014 by dna9656

[Peder_y2k]

Rust and corrosion are the enemy, so if the piston is rusted and/or the cylinder is corroded, replace with new. Otherwise if spotlessly clean, simply replace the seal and reassemble.

-Pete, in Tacoma WA USA

[Marcarl]

if spotlessly clean, simply replace the seal and reassemble.

-Pete, in Tacoma WA USA

That's the operator here, can't be any score marks or dirt. Make sure that the grooves that the seals sit in are spotless as well. It will take some time to clean them out,,, you'll need to clean them, check them, and when you think they are as clean as new,,, clean them again,,, it's gonna take some time so don't rush it.

[Guest bodasefus]

I rebuilt the calipers a few months ago on my 91 VR... I got the pistons out by using air pressure... cleaned the pistons with a scotch brite pad and a solvent. very careful of the O rings but they cleaned up great... lots of calcium buildup... also cleaned out the reserves and found a gel goo in the rear tank but I took a day to do all 3 and install... Took a couple of hours to get the system bleed out ... Works great now... and I can stop...

[dna9656]

I rebuilt the calipers a few months ago on my 91 VR... I got the pistons out by using air pressure... cleaned the pistons with a scotch brite pad and a solvent. very careful of the O rings but they cleaned up great... lots of calcium buildup... also cleaned out the reserves and found a gel goo in the rear tank but I took a day to do all 3 and install... Took a couple of hours to get the system bleed out ... Works great now... and I can stop...

 

 

What are "reserves"? Are you referring to the master cylinder reservoir?

[dna9656]

Well I overhauled the front brakes today. I used air pressure to get the cups out on all but one cup. I had to use the grease gun to get the last one out. It might be safer, faster, but messier to use the grease gun on the cracked open bleeder valve. It's slower than the air pressure but it's CERTAIN! I found crap and corruption behind them thar cups! I used brake fluid as a cleaning solvent with nylon brushes and wooden tooth picks to get the crust out. Rinsed with isopropyl alcohol then 0000 steel wool to get the last bit out and polish the bores a little. Blew them out with compressed air. Used brake fluid to lube everything and pushed the cups back into the bores. Now I'm waiting for the rear kit to arrive!

Thanks to all for the input and advice; as always it's PRICELESS!!!

 

Dna

[cimmer]

Something to check is your brake line hoses. I found on my 89 VR that they were expanding a bit when I applies pressure to them. I replaced them all with a stainless steel brake line kit and along with a rebuild of the brake system, I can stop with no issues. I picked up mine from here. http://www.buckeyeperformance.com/p04.htm

 

Good luck.

Rick F.