Brake Caliper Rebuild

[cowboyup3371]

So I put the rear brake caliper back together this afternoon. I tried to follow the guides on Basscliff's Brakes Odds and Ends page but I just wanted the okay from you all if I did this right.

First, placing the inner seal into caliper:

Second, place dustcover around piston:

Third, pour some brake fluid around cylinder of caliper and use wrag/fingers to wipe around. I didn't put fluid between dustcover and piston so please let me know if I need to redo that part.

Fourth, place piston into caliper and push with hands:

Finished product. Dust covers looks to be uniformly set around the piston and just slightly above the edge:

Thank you all for looking. First time doing brakes here so I'm a little nervous. Oh and thanks to my eldest stepdaughter for taking the first three pictures for me.

 

[Nessism]

Looks good! You are doing fine!

You have stainless steel / Teflon brake lines for when everything goes back together?

 

[jwhelan65]

Great work, just make sure the dust cover boot in pressed into the groove at the top of the cylinder to prevent dirt and moisture from getting in around the piston.

 

[cowboyup3371]

Yep. Got those in a couple of weeks ago...here's the rear brake line.

 

[Big T]

Looks good

Don't forget the O ring that goes in that LH hole in the last pic when you bolt it back together

 

[cowboyup3371]

ARRRGGGGGHHHHHH. I can't find the brake pad shims from my old pads and the new ones don't have them. ray: Does anyone have a spare set they don't want? Or at least know of a suitable replacement I can get somewhere? I'll post this in parts wanted too.

 

[Adler]

isnt the dust boot supposed to also be set on the rim of the caliper?

 

[Big T]

isnt the dust boot supposed to also be set on the rim of the caliper?

Nope, it sits in the groove shown in photo #3

He has the piston pushed in too far in photo #4, so the seal is mashed down

 

[Adler]

Nope, it sits in the groove shown in photo #3

He has the piston pushed in too far in photo #4, so the seal is mashed down

That is the groove on the piston, there is another groove on the caliper that the boot is supposed to fit around.

 

[cowboyup3371]

Nope, it sits in the groove shown in photo #3

He has the piston pushed in too far in photo #4, so the seal is mashed down

The rear caliper is on the bike now but if I have to remove it it's fine. When you say it's too far down, how far should it be? I think I remember it sitting just below the boot so that I could pull the boot off first before pulling up on the caliper. Will I have problems? If so, what kind?

 

[jwhelan65]

That is the groove on the piston, there is another groove on the caliper that the boot is supposed to fit around.

Yes you are correct

 

[Nessism]

These guys are right, sorry I missed it. See how the boot is sticking up above the piston? It shouldn't. The dust boot needs to engage with a lip on the caliper half. You should be able to get it where it needs to be without too much dissassembly.

Oh, and I might have some extra pad shims. Please do me a favor and check the parts fishe to see if they are the same as the shims on a GS1000 caliper.

 

[cowboyup3371]

Thanks Ed and others. I'll take the caliper off the bike tonight and fix it.

 

[cowboyup3371]

Which is right?

Which is right?

So I tried to redo it this morning...which one looks right to you? I am sure the boot is seated around that groove at the top of the piston.

 

[Adler]

There are two lips that it needs to go over....
First it needs to slide into the lip on the piston... done
Now you need to pull it over the lip on the caliper... See that lip?

 

[Nessism]

Yes, as the other have said, the boot needs to engage the lip on the caliper body. The arrows point to the grooves the boot should fit into.

 

[jwhelan65]

As seen in the pic from Ed, the rim of the boot tucks in the groove on the caliper along side of the piston. Use a very small blunt screw driver and slowly tuck it down in the groove if you have to. The boot should not spin around the caliper when it is in place.

 

[cowboyup3371]

okay I will try it again when I get home tonight. Thank you for the help and I'll post pics again when I am done.

 

[cowboyup3371]

ARRRGGGGHHH I hate cats. The little itty bitty o-ring that you told me to make sure went in to the calipers is now gone. IF you look up at the pictures above you can see I already had it in place when I tore them apart again this AM. Well, I finally got the boots seated the correct way that you all told me and got ready to put the caliper back together when I noticed it was missing. I think my daughter's new kitten played with it and lost it on me. Does anyone know what size that thing should be so I can find a cheap substitute since the parts fiche shows it running around $10?

Also, Nessism, those shims are used on your bike.

Thanks for helping me out guys. I'm sure glad I was able to turn to you all.

On edit - never mind about the size...Nessism had a spare he's willing to send me. Looks like I'm still on track to get the bike running next week again.

 

[Jagir]

great pics

great pics

I am finding this thread very helpful right now, thanks.