impossible task of fitting rubber boot to brake caliper

[Guest]

Hi,

I'm having a hell of a job fitting the boot to my rear brake caliper. There is only the smallest of ridges for the boot to fit the boot lip on the brake, or maybe it goes around something rather than in something, or maybe this brake has no boot? Can anyone tell me the exact technique, I can't believe it that it's so difficult.

Cheers

Dave
Suzuki GS1000G 1980.

 

[Guest]

for instance is it 1 or 2, I think it is 1 but then 1 is hardly a ridge at all and the rubber boot refuses to sit there

 

[1978GS750E]

I've had luck with taking those boots and dropping them in boiling water for a minute or so. Seems to shrink the rubber after they cool?? Might be worth a try?

 

[oldGSfan]

I've done several of those and it's a puzzle each time as my memory is shot from too much, umm, clean living. I just did them a few months ago on my '82 GS1100E and will be doing again on my '79 GS1000E. As I recall (ummm...) they just slot lightly into that inner ridge, I used a bit of silicone brake grease. I recall thinking "can that be it?" but with them all the way settled in it's enough grab to keep them seated.

 

[Guest]

I just cant believe that this tiny ridge is supposed to hold the boots. If I compare with other brakes (eg car brakes) there is a proper deep groove and the boot fits well. In fact if I were to design this thing I would make the boot go over something, then the stretchyness of the rubber would hold it. The groove in the piston, that's fine, why can they not do something similar for the calipers? I want to hunt down Mr Yakimoto or whoever and give him a piece of my mind!

 

[Nessism]

I'm having a hard time remembering but seem to think the boot goes on the outside of the lip, where arrow 2 is pointing.

 

[1978GS750E]

I think that is correct Nessism. That's why I try to shrink them before installing. That lip is really small and if the boot has stretched, it does not want to stay in place.

 

[Burque73]

I went through that a few months ago. The silicone brake grease definitely helped get the boot back on.

Here a couple of pics if they help. Before and after. Sorry, I don't remember the order of assembly. Just fumbled with it till it went together.

 

[Guest]

Definitely on the outside then (nice little joke of Suzuki to do a fake inner ridge ).
Thanks for clearing that up. But it's strange because when I did the front brakes the boot went into an inside groove, unless of course I did something wrong?

Cheers

Dave

I went through that a few months ago. The silicone brake grease definitely helped get the boot back on.

Here a couple of pics if they help. Before and after. Sorry, I don't remember the order of assembly. Just fumbled with it till it went together.

 

[Guest]

That's a good tip. But I have new boots so they'll probably be ok.

 

[Wingsconsin]

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 :drunk: :drunk:

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

 

[Guest]

Yes, beer to dull the frustration, good idea!

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 :drunk: :drunk:

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

 

[650Skull]

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 ....

 

[Wingsconsin]

​This process is more ART than SCIENCE --

 

[bwringer]

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.

 

[Guest]

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

 

[Guest]

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.

 

[Guest]

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