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Post by eliminator on Apr 22, 2008 19:23:37 GMT
You have a pm
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Post by taint on Apr 24, 2008 14:23:08 GMT
I have a resolution! Sort of... ;D I dropped the calliper into Breaking Point (local bike garage/breaker) yesterday; to see if they could remove the remains of the old bleed screw. Dropping in today to collect it, they'd been unable to remove the stump, but they had capped the old screw and had a brand new bleed banjo bolt; which was something I'd never heard of before. They'd also cleaned and greased the pistons ready to go  Course I still need to replace the pistons and the remaining bleed screw; but at least it should be easy now! Now I have to wonder if it's possible to get a stainless version of this Bleed Banjo bolt; cause all the other fittings are stainless   So at least I should be able to put it all back together again. The second calliper is still on its way to you eliminator; it doesn't make sense to have a useless spare sitting around, plus Cams may still want it. I'll update once it's actually put back together again ;D T. |
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Post by taint on Apr 24, 2008 23:43:42 GMT
It's absolutely typical; I finally manage to get a calliper I can put on the bike and then I realise that the bleed screws I ordered with my Hel Brakes lines months ago... are the wrong size! So, yet more waiting  T. |
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Post by eliminator on Apr 28, 2008 18:00:33 GMT
Jeez, this caliper is a mess! I haven't pumped it up yet. I see what you meant about someone welding the inside of the pistons  More reporting tomorrow night. |
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Post by taint on Apr 28, 2008 22:15:26 GMT
The opinion of the breaker was that the caliper body was in decent condition, even if the pistons weren't. Considering how it looked to start with; I was pretty pleased with how it had cleaned up ;D I dread to think what the internals are going to look like Thanks again T. |
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Post by taint on Apr 28, 2008 22:18:38 GMT
Oh, and when the guy at the breakers put the other calliper back together again, he obviously didn't believe in using dust seals; because they were missing from both pistons. The grooves were filled with red rubber grease Seriously glad I decided to clean them thoroughly and refurb them.  T. |
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Post by General Gman on Apr 29, 2008 8:42:29 GMT
I stripped the rear caliper on my ZX9 last night cos I was fitting new pads - had the seals out, and *shock* *horror* - there was no crud behind the seals, they were in perfect condition. How happy was I ?  |
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Post by Deleted on Apr 29, 2008 9:17:04 GMT
I stripped the rear caliper on my ZX9 last night cos I was fitting new pads - had the seals out, and *shock* *horror* - there was no crud behind the seals, they were in perfect condition. How happy was I ? You've gotta start riding it instead of Helga. |
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Post by taint on Apr 29, 2008 9:17:14 GMT
For fsck sake  can't anything go right? I've just received the replacement bleed screw and guess what... It's the wrong size again! I now have 3 spare Stainless M8 x 1.25 bleed screws when I really need M7x1.0 I've placed yet another order; hopefully I'll get the correct thing this time. T. |
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Post by General Gman on Apr 29, 2008 10:41:39 GMT
I stripped the rear caliper on my ZX9 last night cos I was fitting new pads - had the seals out, and *shock* *horror* - there was no crud behind the seals, they were in perfect condition. How happy was I ? You've gotta start riding it instead of Helga. Oh, I do... just use the divvy for work so I don't square my tyres off. Never use the back brake, so was expecting it to be seized to buggery. Happy days |
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Post by eliminator on Apr 29, 2008 17:05:35 GMT
Blew one piston out no problem.
But this is the problem! When I blew my seized pistons out, I cleaned the grooves out & fitted new seals. Then I pushed the new piston back in, held it in place, fully home. Then blew the other piston out.
What I'm saying is that I can't blow both pistons out at the same time.
Second piston will come out, it was stiff at first, but 800psi has a strangely influential effect!
I'll have another go at blowing the second piston fully out at work tomorrow. (if I have the time)
If? WHEN! this one comes out, i'll return it to you. The first piston should blow out with an airline, now that it has tasted freedom.
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Post by taint on Apr 29, 2008 19:48:41 GMT
Great news ;D Glad to hear that they came out, even if it was with a little coercion Don't worry about too much about the pistons and seals; I have a complete replacement set ready to go in. If any of the parts do end up costing you money, let me know and I'll reimburse you. Thanks again T. |
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Post by eliminator on Apr 29, 2008 20:05:55 GMT
No, the second piston has not been out completely. What I'm saying is that I'll blow the second piston out (as it is the tighter of the 2) & return the caliper to you, with the first piston still in place. then you can put new seals in place & blow the other one out with an air line, as it will have eased somewhat.
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Post by taint on Apr 29, 2008 20:50:50 GMT
Sorry for misreading your posting. It's still good news that one of them has shifted If you're able, can you leave the first piston sticking out about 5mm? Unfortunately, I don't have access (currently) to an air compressor (looking to invest ) so I just need enough to get a pair of molegrips onto. Thanks again T. |
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Post by eliminator on Apr 29, 2008 21:27:32 GMT
Hopefully it will be loose enough to blow out using a foot pump.
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Post by amorti on Apr 30, 2008 10:25:14 GMT
You're either really unlucky, or you need some better tools.
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Post by taint on Apr 30, 2008 10:47:13 GMT
Lol, my wife would kill me if she heard that; I've already shelled out more than enough on tools lately ;D My recent purchases include a set of Snap-On Blue Point 3/8" tools and a few other bits and bobs . Seriously nice quality tools. T. |
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Post by eliminator on Apr 30, 2008 16:51:28 GMT
One piston removed & binned. Hmmmmm, no evidence of a dust seal being in place!
I'll get the turner to make up a blank, so that I can seal the open side, then I'll blow the other one out.
Taking a bit longer than I thought it would though. I have a blank, but it is for the front caliper & the pistons are smaller.
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Post by taint on Apr 30, 2008 18:52:22 GMT
I'm glad to hear you're having success; your help is truly appreciated ;D I'm definitely owe you a drink at some point, if you're not going on the Scotland run I'll organise something I'm guessing that the piston was in a fearful state I'm again puzzled to hear that the dust seal was missing Like I say, there's no hurry to get that calliper back; take as much time as you need. The other calliper has now been painted and is ready to reconstruct, I just need to wait for the bleed screw to turn up and then I'll get it fitted and bled. Then I just need an MOT certificate. Thanks again T. |
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Post by taint on May 6, 2008 18:37:48 GMT
The calliper has now been fitted and bled. It looks pretty sweet now that it's painted and fitted with all the stainless and braided hoses. I have to admit it now looks better than the front I'm half tempted to re-strip and repaint the front ;D If I can I'll grab a photo of the finished job and post. Thanks for everyone's help T. |
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Post by taint on May 7, 2008 22:33:25 GMT
 I know, pretty sad posting photos of a calliper ;D T. |
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Post by m40man on May 8, 2008 7:29:04 GMT
I know, pretty sad posting photos of a calliper ;D T. Well quite ;D. But since you've proven quite good at refurbs, can you fix this one for me:  . |
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Post by taint on May 8, 2008 7:46:13 GMT
Ouch, that one doesn't look all that healthy What on earth happened to it? Well, at least it looks like the internals are undamaged; but I'm not certain how safe the mount point will be I'm guessing you've already written it off? T. |
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Post by eliminator on May 8, 2008 16:20:48 GMT
Both pistons blown out, posted back to you this afternoon.
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Post by taint on May 8, 2008 17:37:59 GMT
You have my sincerest thanks Eliminator ;D Do you prefer Red, White or Whisky? T. |
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Post by ando7p on May 8, 2008 18:16:49 GMT
Well, you're a persistant burger aren't you? Hats off to you mate. I gave up with refurbing my rear as it was so bad. Got a good one from a 2001 for 45 quid.
Now if only the thrust bearing on the clutch wasn't crackered ......
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Post by teejayexc on May 8, 2008 18:39:15 GMT
You don't want to know! (do you?) *bugger* sounds like you do know I doubt it. He's already run over it though(*bugger* now you do know) ;D
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Post by eliminator on May 8, 2008 20:35:59 GMT
There wasn't a dust seal in the other side either! Both seemed to be full of copper grease, which is not a good idea. as apart from obviouslt leaving out the dust seals, I believe that copper grease can damage rubber seals.
I binned the pistons, waste of time returning them to you.
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Post by taint on May 9, 2008 9:16:58 GMT
Calliper received with thanks Next day delivery; not bad for second class postage ;D What a state the interiors are in! hopefully nothing a wire brush won't cure ;D I had planned on binning the pistons anyway, so that saves me a job I had spotted the copper grease and I did have to wonder which bright spark had put it there  Aside from rotting the seals, the copper will accelerate the corrosion of the calliper alloy and the high viscosity would impede piston movement; as we already noticed Cheers, T. |
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Post by General Gman on May 9, 2008 10:27:53 GMT
I was looking on ebay at 6 pot calipers this week, and one bloke had cleaned the calipers beautifully, everything was gorgeous... until I looked at the pic he took of the pistons with copper grease all over them.What a tit !
As for the dust seals.... I've been known to discard them cos often they are more trouble than they're worth.If I do, I pach the grooves with rubber / silicone grease and just clean them a lot more often - only takes 10 mins a week to clean the brakes.
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can't anything go right?
Aside from rotting the seals, the copper will accelerate the corrosion of the calliper alloy and the high viscosity would impede piston movement; as we already noticed