How do I refurbish front nearside caliper?

[macafee2]

Originally Posted by vitesse

Doing the same job but on my daughter's ZS180, both front brakes binding and it's the pistons at fault. Usually I manage to remove the pistons with compressed air (good 12 bar compressor) but these won't budge. Had to tap them out using a cold chisel - one out, one to go. Tea break at the moment. Cleaning with Autosol chrome polish and a rotary cotton pad.
Brakes International are very good, and rather than eBay I'd use their own website. Takes too long to order from UK nowadays so I'm cleaning and hoping for the best.

Regards

thanks. went to their web site but it is cheaper via ebay so have ordered a kit from their ebay listings

nacafee2

[clf]

Originally Posted by macafee2

thanks. went to their web site but it is cheaper via ebay so have ordered a kit from their ebay listings

nacafee2

better late than never, and just in case you didnt find it (I gave you a bum steer on how to find it)

the video I referred to HERE - Also THIS video shows a guy fitting a repair kit which may show you what you are doing too (the dust boot is different on this one compared to the front. The front dust boot more or less just clips on by comparison! - interestingly, these are the same as our rears) .

They are slightly different, but the principles are the same.

I have only rebuilt the 190 set up, buying a set and doing them off the car. But the seals are similar there too.

Make sure the area that the seals mount are clean and smooth. Aside from it sealing properly, it will mean they fit easier. It will go together easier than you would imagine too.

One thing to keep an eye on is the piston seal. There is a very slight ridge that maintains the seal around the piston, whilst allowing it to retract relatively easily. I imagine this could be easy to get the wrong way around if working on it on the car.

[macafee2]

I have had pistons out of motorbike calipers ..... and lived to tell the tale

Thanks for the heads up about the ridge.
Going to buy a spark plug wire brush to clean up where the dust cover fits. I may have to go to the lock up to get a G clamp for putting the piston back in, I doubt I will get in in by hand. Will also try to find my hose clamps. Bleed nipple should come undone as I bled the brakes and changed the brake fluid during lock down last year

macafee2

[vitesse]

Originally Posted by macafee2

I have had pistons out of motorbike calipers ..... and lived to tell the tale

Thanks for the heads up about the ridge.
Going to buy a spark plug wire brush to clean up where the dust cover fits. I may have to go to the lock up to get a G clamp for putting the piston back in, I doubt I will get in in by hand. Will also try to find my hose clamps. Bleed nipple should come undone as I bled the brakes and changed the brake fluid during lock down last year

macafee2

As I wrote, after polishing the piston and cleaning the seal/dust cover grooves, I was easily able to push the piston back in just using an old brake pad - without any fluid there's not much resistance. Biggest problem was fitting the dust cover, but eventually fitted the dust cover to the removed piston first, then gradually with the piston at an angle pressed the dust cover into its groove, using a thin feeler gauge to get the last bit tucked in. (nb: not 75 but ZS180). Got the other side to do today and have soaked the brake nipple in preparation.

Good luck

Will check for a lip on the main seal as I didn't notice any yesterday, useful tip.

[macafee2]

repair kit arrived less than 24 hours after being ordered.

I have checked the seal for a lip and there is not one so no risk of putting it in upside down / back to front

macafee2

So I've been having a right nightmare with the caliper rebuild. I'm finding it really difficult to get the dust cover to seat correctly. I've started at the hardest bit of the caliper and worked a screwdriver around but it just keeps popping off as you go around wherever your screwdriver isnt. Any advice guys? I've managed to pierce 2 covers now so I'm calling it quits for the weekend until I can get some more.

[macafee2]

Originally Posted by GutsyDogWagon

So I've been having a right nightmare with the caliper rebuild. I'm finding it really difficult to get the dust cover to seat correctly. I've started at the hardest bit of the caliper and worked a screwdriver around but it just keeps popping off as you go around wherever your screwdriver isnt. Any advice guys? I've managed to pierce 2 covers now so I'm calling it quits for the weekend until I can get some more.

use the old dust cover. For the life of me I could not get the new one on, I even got on to the retialer who sent me a new replacement but I fitted one from a spare caliper.

macafee2

Not an option for me I'm afraid macafee, the old one perished into chunks as I was taking it off. At least it's not just me then I thought I was doing something really wrong.