1980 GS550E - Front Caliper Rebuild

[081dbx64]

Just passing along my recent project. I rebuilt my front brake caliper and while I was at it repainted it. Let it dry overnight and put it back together.

A couple of tips.

I got the piston out by wrapping a piece of rubber around the banjo bolt and secured it with a small hose clamp. This allowed me to put my air compressor nozzle into the bleeder screw hold and pressurize the caliper. The piston came right out. I did'nt have a rubber tip compressor nozzle.

See banjo bolt

http://picasaweb.google.com/lh/photo/7ZJy13d5y51n3G5Xakl1vw?feat=directlink

Putting it back together was a challenge because I did not want to get any fluid on the new paint. I did not place any brake fluid on any parts until I had the piston in and sealed. See this photo.

http://picasaweb.google.com/lh/photo/2EzoQ26a3ew79iZqJQN4Tw?feat=directlink

Basically I let the seal that goes around the piston hand over the end and placed it into the caliper. Kind had to work it for a while to get it to set. Then once it was set I pressed the piston until it just started to go in.

The I put the banjo bolt with the rubber and hose clamp on it into the threaded hole. Took out the bleeder screw and carefully with a Dixie cup poured about a table spoon of brake fluid in. Replaced the bleeder screw.

Now that the unit was sealed I just allowed the brake fluid to soak into the seals. After a few minutes I pressed the piston into final position.

No brake fluid leaks on my new paint!


All and all it went well. This was the first time my system was flushed and the seals replaced. 30 years and 18,000 miles.

Before Pics

http://picasaweb.google.com/lh/photo/yf_3PLe8YQ6MoSZ_zIbVrA?feat=directlink

http://picasaweb.google.com/lh/photo/VLT3E-5NZkc-kFaVtbjl7w?feat=directlink

http://picasaweb.google.com/lh/photo/yOuDcVeumWxbw_Uc1ooCrw?feat=directlink

 

[Nessism]

Nice work. Good to see someone doing a proper caliper clean out instead of just pushing new fluid though.

Your rubber brake line is dated 10/'79 in one of your photos! Hope you threw that thing in the trash and got a new one.

 

[081dbx64]

Yes I know..they are original. I have yanked and pulled on they and they are still soft and no cracks. It's one of the next things on my list to make some new ones.