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Subject if the pistons won't blow out using compressed air do this>
     
Posted by my91z on March 04, 2002 at 12:41 PM
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In Reply To Re: Powdercoating calipers: What special prep work is needed posted by Oppaman Z on March 04, 2002 at 12:25 PM
     
Message I rebuilt the calipers on a motorcycle of mine and one of the pistons would NOT budge using full pressure shop-air. I ended up going to a hardware store and getting an adapter to fit in the caliper that had internal threads that fit a grease zerk. Then I split the caliper and drilled holes in a piece of aluminium and mounted it over the crossover holes between the caliper halves to seal up the side I was working on. On the front calipers you might be able to just put a piece of wood between the two pistons you are not worried about, and rig up a way to stop the piston opposite the stuck one from comming out. I had single piston calipers on the bike so didn't have to worry about another set getting pushed out by the grease. Also, I split the caliper so I wouldn't have to fill such a large volume with grease, and would have less mess to clean up.

Anyway, that method worked great, and the piston comes out nice and slowly, so you don't damage anything or injure yourself. I would replace the seals as a matter of course after that, and since you have the calipers apart anyway.

One other thing, brake seals an WD-40 do not mix, lol. It make them swell, and the seal over the master cylinder as well. I tried filling the system with WD-40 first and operated the brake lever hoping it would penetrate and free up the piston. Not a good idea, lol. And the piston was so firmly stuck that the MC couldn't generate enough pressure to pop it out.

Mike

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