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Thread: impossible task of fitting rubber boot to brake caliper

  1. #11
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    When I struggled my way through this about a year ago I was really discouraged as it seemed impossible

    Then I decided to stay patient and use a little brake fluid as a good lubricant and work them OVER that edge slowly -
    Start at one point and run your fingers around the circle in both directions until you get back together -
    Of course one edge will pop off once you think you have it -- but suddenly and without warning it will stay ON -
    You will feel emboldened and try another - only to face more frustration -

    I will rate this work at -- 2 beers

    I doubt that explanation helps any - but I hope you were entertained a little
    Currently in the Stable :
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  2. #12
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    Yes, beer to dull the frustration, good idea!

    Quote Originally Posted by Wingsconsin View Post
    When I struggled my way through this about a year ago I was really discouraged as it seemed impossible

    Then I decided to stay patient and use a little brake fluid as a good lubricant and work them OVER that edge slowly -
    Start at one point and run your fingers around the circle in both directions until you get back together -
    Of course one edge will pop off once you think you have it -- but suddenly and without warning it will stay ON -
    You will feel emboldened and try another - only to face more frustration -

    I will rate this work at -- 2 beers

    I doubt that explanation helps any - but I hope you were entertained a little

  3. #13
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    I like to take lots of pics as i disassemble things........I'm good at taking things apart and without some visual record they usually stay apart ....
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  4. #14
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    ​This process is more ART than SCIENCE --
    Currently in the Stable :
    2002 Honda Goldwing GL1800 Sunburst Pearl Orange
    1983 Suzuki GS850 GL Blue & Black

    " I am never lost until I run out of fuel...until that moment I am EXPLORING."
    - Carl R. Munkwitz

    Munk's Maxim: "There is no such thing as a cheap motorcycle"

  5. #15
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    I can do it after some minutes of fumbling, and I've done it many times, but I honestly have no idea how to describe the process in a helpful way.
    1983 GS850G, Cosmos Blue.
    2002 DL1000 V-Strom, Dark Metallic Space Blue.
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  6. #16
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    So first a disclaimer: "I am in no way a brake caliper specialist"! When I recently did the front calipers on my 79 GS850 it took me at at least an hour and a half trying to get the dust boots in place and the piston mounted afterwards to do the first one. I put the second one aside and did it the next day. When looking at the boot retainer I noticed that the material was different than the caliper so I gently took a flat blade screwdriver and very carefully pried the retainer up and out. I then put it in the seal and pushed the retainer with the rubber seal back into the caliper with my fingers, then merely got ahold of the rubber seal and pulled it up and around the piston, pushed the piston in and the seal snapped into place on the piston. Whole procedure took maybe 5 minutes and a lot less frustration and curse words. Hope this makes sense
    Jonesz

    1979 GS850 current project
    1978 GL1000-naked
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    1999 Valkyrie Tourer-long ride bike

  7. #17
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    For the front calipers, the rubber goes on the inside of the cylinder. On the rear it goes on the outside.

    Bit of a fumble, but will stay in place if the rubbers are new.
    1996 GSF1200 Pretty Much Standard.
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  8. #18
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    Ok, I managed to get the boots on today (the snow has melted so it gave me a bit of encouragement). My technique was in the end, put boots on piston, make sure that they are the right way round and that they expand properly (because if the top lip is trapped inside it won't come out again. Then put the piston against the inner seal and with all my fingers trying to clamp the bottom lip and work it round the circle, eventually work the lip over the outer edge. Then when that's done push the piston past the seal a bit, then side the top lip up to the piston groove. I think a lot of my problem was because the external groove had filled up with road gunge (thanks previous owner for running it without a boot!).

    Cheers

    Dave
    Last edited by DaveWatts; 02-22-2021 at 02:06 PM.

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