Assembling front caliper 1980 GS850G

[uteman]

I am trying to refit pistons to my front calipers.
No problem fitting the piston seal but can anyone give me some advice of what method to fit dust seal which of course fits to both the piston and the caliper body.
What process have you found works best?
Do I fit the dust seal to the piston or caliper body first?
Regardless of which it gets fitted to first how do I finish the task?
If I fit the dust seal to the caliper body first then it is difficult to get the piston through the dust seal into the body.
If I fit the dust seal to the piston then it seems almost impossible to get the dust seal into the groove in the caliper body once the piston is in the caliper body.
The manuals that I have just seem to assume I know how to do it as they just advise that I should reassemble!

[Rijko]

i fit the seal ring inside the body first, use some brake oil to wet the rubber before mounting.
Next, also wet the outside of the clean piston with brake oil so it will slide in easily.
Rotating the piston slowly left-right while sliding it in.
If it is half way in, leave it and wipe off excess brake oil.
Place the dust seal rubber in the groove on the piston and slide the piston in further,
pushing it straight down with both thumbs.
Now you should be able to install the dust seal rubber into the groove of the body easily.

[Rijko]

check out these 2 excellent guides, nice pics and tips in there.
Now you've got 3 different ways of doing it from 3 different people,
choose your preferred way
If you are going to use a paperclip, be careful not to damage the rubber.

http://gsarchive.bwringer.com/cbsaunders/gs/79-Brake_overhaul.pdf

http://gsarchive.bwringer.com/storagecliff1/images/brake_caliper_overhaul.pdf

[uteman]

Thanks Rijko

check out these 2 excellent guides, nice pics and tips in there.
Now you've got 3 different ways of doing it from 3 different people,
choose your preferred way
If you are going to use a paperclip, be careful not to damage the rubber.

http://gsarchive.bwringer.com/cbsaunders/gs/79-Brake_overhaul.pdf

http://gsarchive.bwringer.com/storag...r_overhaul.pdf

As it is night time in the land down under I will get to the job in the morning and let you know how I go.
Somehow I have managed to do this job previously but the old brain is bit slow now.

[Rijko]

you're welcome. Good night and good luck tomorrow.

[chuck hahn]

I set the boot at the very bottom of the piston base and set the rib into the bodys groove. Then just shove the piston home. A small tipped flat screw driver helps with setting the rib into the groove.

[uteman]

chuck hahn & Rijko:
I got the job done and really appreciate assistance.
I actually got one done using a paper clip but reverted to putting the seal at bottom of piston for 2nd one. That seemed much easier.
This bike is near to going on the road after a frame up rebuild.
Can you answer me this: There is a section on the forum that asks for info on resto's etc. yet it seems that only one photo can be posted so a little difficult.
I would be happy to share my work if I knew how.

[cowboyup3371]

There is a forum limit of one photo per post if you just upload to it. Most of us will use something like photobucket or imgur where we can then upload 10 photos per post. You can find instructions on how to post photos at Basscliff's site - http://members.dslextreme.com/users/bikecliff

[Rijko]

i'm glad it worked out !

I'm sailing atm enjoying the sun, uploading 1 picture per post is correct but
if the pictures are on a website like Photobucket you can put more pics in 1 posting.
Hope this manual is of help.

[uteman]

Rijko & cowboyup: Thx for info on posting pics