"Easy" Caliper piston removal - Steve Saunders Goldwing Forums

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post #1 of 16 (permalink) Old 01-28-2009, 07:28 PM Thread Starter
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I read a discussion here not long ago about removing frozen brake caliper pistons.

I've had to do a lot over the years but a pair of frozen calipers I recently got off ebay were not at all amenable to my usual ways.



In the past I have always managed to remove them with compressed air, while they were wrapped in a large towel to protect me.



I read here about using a grease gun + zerk.



They came out so easily with hardly any physical effort on my part.



I took a 10mm diam bolt with a 1.25mm thread pitch & cut the bolt to 10mm length. I then drilled through it lengthwise a hole with a #3 wire gauge drill & tapped the hole at the head end with a 1/4" x 28 tap. Fitted a grease zerk, screwed bolt into caliper & pumped away. The frozen piston slowly came out. No damage to it or the caliper bore.







A big thank youto whoever suggested that.



Now I have to take apart a frozen master cylinder....any tips?


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post #2 of 16 (permalink) Old 01-28-2009, 07:42 PM
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some pics would be great, congratulations seems like a great way to do it.
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post #3 of 16 (permalink) Old 01-28-2009, 07:46 PM
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Why not get a zerk fitting to fit in the hole for the bleeder valve and cap the hose line fitting? Would seem easier to do to me. Good idea which ever way you go with it, I like it!!

Michael
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post #4 of 16 (permalink) Old 01-28-2009, 08:48 PM Thread Starter
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I used what I had in my garage. Didn't have a zerk to fit the bleeder thread. Too cold & snowy here to go searching auto parts stores.
Took about 15 mins to make the piece.

2006 Suzuki Burgman 400
1982 GL1100 Aspencade
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post #5 of 16 (permalink) Old 01-28-2009, 10:34 PM
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Excellent idea. I'll either find a zerk to fit or fab one like you did. It's rear caliper time boys and girls!
Jim(inSC)

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post #6 of 16 (permalink) Old 01-29-2009, 04:30 AM
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The way I got my frozen pistons out was: With the caliper still connected, I put a c-clamp on one piston to hold it in and used the master cly.to push one piston almost all the way out. I took the c-clamp off and put it on the other piston to hold it in place, added more fluid and pushed the other piston out. Then the other one came out with a little wiggling

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post #7 of 16 (permalink) Old 01-29-2009, 05:20 AM
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wing ding wrote:
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The way I got my frozen pistons out was: With the caliper still connected, I put a c-clamp on one piston to hold it in and used the master cly.to push one piston almost all the way out. I took the c-clamp off and put it on the other piston to hold it in place, added more fluid and pushed the other piston out. Then the other one came out with a little wiggling
You can always take a couple of brake pads and stick it in the caliper, then pump up the brakes. Remove a pad and repeat. Make the spacer thinner and thinner that way the pistons come out equally. But yes, much easier to remove the pistons while they are in the bike and full of fluid. Grease works, but has to be much harder to clean up afterwards.

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post #8 of 16 (permalink) Old 01-29-2009, 08:35 AM
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53jimc wrote:
Quote:
Excellent idea. I'll either find a zerk to fit or fab one like you did. It's rear caliper time boys and girls!
Jim(inSC)
Not to hijack the thread but, Jim, did you get your carb gauge set yet and get your carbs synced?

Michael
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Have trailer, will travel!! Not all Wingers are old Wingers.

PGR member. Riding in memory of my father, Clyde D. Ward, USN. WWII

Myself, USN, Vietnam Vet. 68-72, 74-76
VF-194 aboard the USS. Oriskany
USS Saratoga, ships company

-----------------------------------
Bagmaster, our former forum Toolmaster and friend, is no longer with us. He passed away in February 2012.

The roads and byways, no matter how beautiful and exhilarating, are a lonelier place now. RIP Bagmaster (Baggy).
-----------------------------------
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post #9 of 16 (permalink) Old 05-26-2012, 07:18 PM
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Yeah that's a good tip. I like to put them in the oven at about 250 deg F if they are really stuck and then they usually come out with compressed air. Mind you I don't reuse the piston seal after that!
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post #10 of 16 (permalink) Old 06-13-2012, 07:17 PM
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With the caliper off the bike I installed the old pads, then I placed an air gun with the rubber tip against the nipple opening (nipple removed) and gave it a shot of air. Both pistons come out against the pads just fine.

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