Brake caliper rebuild: Difference between revisions

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[[Category: Brakes]]
[[Category: Brakes]]
Everything you need can be found at Autozone or Advance Auto Parts.
 
For more information and pictures, see[[How do I replace the brake pads?]].
 
Supplies are pretty basic. Everything you need can be found at Autozone or similar stores.  


* DOT3 or DOT4 brake fluid [http://faq.ninja250.org/wiki/How_do_I_change_the_brake_fluid%3F#What_kind_of_brake_fluid.3F DOT4 preferred]
* DOT3 or DOT4 brake fluid [http://faq.ninja250.org/wiki/How_do_I_change_the_brake_fluid%3F#What_kind_of_brake_fluid.3F DOT4 preferred]
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Remove the two 12mm bolts attaching the caliper to the fork.
Remove the two 12mm bolts attaching the caliper to the fork.


 
[[image:123-1.jpg|150px]]


Gently remove the little brake pad and set it aside.
Gently remove the little brake pad and set it aside.
Line 22: Line 25:
Pull back (compress) the caliper bracket, thus pushing the caliper guide pins in as far as possible.
Pull back (compress) the caliper bracket, thus pushing the caliper guide pins in as far as possible.


 
[[image:123-1.jpg|150px]]


Shift and tilt the big brake pad so it looks like this
Shift and tilt the big brake pad so it looks like this


 
[[image:123-1.jpg|150px]]


Push one edge of the brake pad over the caliper pin allowing you to easily remove the other side shortly thereafter.
Push one edge of the brake pad over the caliper pin allowing you to easily remove the other side shortly thereafter.


 
[[image:123-1.jpg|150px]]


Your caliper should now look like this.
Your caliper should now look like this.


 
[[image:123-1.jpg|150px]]


Remove the anti-vibration bracket (take note of its orientation).
Remove the anti-vibration bracket (take note of its orientation).


[[image:123-1.jpg|150px]]


 
Remove the ceramic (plastic) inserts inside the caliper pistons.
Remove the ceramic inserts inside the caliper pistons.


Pump the brake lever CAREFULLY and GENTLY and work both pistons with your thumbs so that both pistons slowly pop out TOGETHER.
Pump the brake lever CAREFULLY and GENTLY and work both pistons with your thumbs so that both pistons slowly pop out TOGETHER.
About 150mL +/- 100mL brake fluid will spill out, so be prepared with a catch container below your working area.
About 150ml of brake fluid will spill out, so be prepared with a catch container below your working area.
 


[[image:123-1.jpg|150px]]


Remove all FOUR seals inside the caliper. You will want to clean these carefully and very thoroughly. There is a LOT of dirt and god knows what else inside and behind these seals. This is why you should rebuild your caliper from time to time.
Remove all FOUR seals inside the caliper. You will want to clean these carefully and very thoroughly. There is a LOT of dirt and god knows what else inside and behind these seals. This is why you should rebuild your caliper from time to time.


 
[[image:123-1.jpg|150px]]


Reassemble all seals. Put one side of the seal in first, then work both ways around the rubber rings until they seat completely.
Reassemble all seals. Put one side of the seal in first, then work both ways around the rubber rings until they seat completely.


[[image:123-1.jpg|150px]]


 
Pull out the caliper bracket assembly (the rubber boots should be worked off the bracket gently). One side of the caliper has a rubber boot which cannot be removed. Do not even try or you will destroy it. Clean it in place.
Pull out the caliper bracket assembly (the rubber boots should be worked off the bracket gently).
 
One side of the caliper has a rubber boot which cannot be removed. Do not even try or you will destroy it. Clean it in place.


Clean and then lubricate the pins generously.
Clean and then lubricate the pins generously.


[[image:123-1.jpg|150px]]


Spray tons of brake cleaner into the two caliper pin guide holes and make sure you get all of the old crud out. Then, insert a bunch of grease with your finger. The aftermath should look like so.


Spray tons of brake cleaner into the two caliper pin guide holes and make sure you get all of the old crud out.
[[image:123-1.jpg|150px]]
 
Insert a bunch of grease with your finger thereafter.
 
The aftermath should look like so.
 
 
 
Lubricate and insert the clean pistons.


Lubricate and insert the clean pistons. Some people say to use brake fluid as lube; others use brake lube, as shown.


[[image:123-1.jpg|150px]]


Push the pistons in with your thumbs until they are flush with the adjacent metal surface.
Push the pistons in with your thumbs until they are flush with the adjacent metal surface.


[[image:123-1.jpg|150px]]


Insert the plastic (ceramic) inserts.


Insert the plastic inserts.
[[image:123-1.jpg|150px]]
 
 


Install the anti-vibration pad.
Install the anti-vibration pad.


 
[[image:123-1.jpg|150px]]


Install the big brake pad.
Install the big brake pad.


 
[[image:123-1.jpg|150px]]
 
[[image:123-1.jpg|150px]]


The tabs must face the bottom - not the top - of the brake pad.
The tabs must face the bottom - not the top - of the brake pad.
Line 96: Line 93:
This is the incorrect (and opposite) way to install the small brake pad. Don't mess this up!
This is the incorrect (and opposite) way to install the small brake pad. Don't mess this up!


 
XXXXXXXXXXXXXX SHOW PICTURE FROM PAD REPLACEMENT ARTICLE. XXXXXXXX


Reinstall the caliper.
Reinstall the caliper.


 
[[image:123-1.jpg|150px]]


Bleed the brakes per the FAQ.
Bleed the brakes per the FAQ.
Line 108: Line 105:
After bleeding, let the bike rest overnight with zip ties installed like so.
After bleeding, let the bike rest overnight with zip ties installed like so.


[[image:123-1.jpg|150px]]


Stand on the rear brake while installing these zip ties (this can be a little tricky).


Stand on the rear brake while installing these zip ties (this can be a little tricky).
[[image:123-1.jpg|150px]]

Revision as of 02:21, 27 October 2011


For more information and pictures, seeHow do I replace the brake pads?.

Supplies are pretty basic. Everything you need can be found at Autozone or similar stores.

  • DOT3 or DOT4 brake fluid DOT4 preferred
  • Permatex brush-top ultra disc brake caliper lube or similar brake lubricant
  • Disposable nitrile gloves (don't skimp on this one)
  • Brake cleaner
  • Plenty of paper towels
  • Dentist's-type pick or tiny flat head screwdriver
  • Heavy duty large zip ties

Throughout this process, use copious amounts of brake cleaner on every dirty part, then wipe and dry thoroughly.

Remove the two 12mm bolts attaching the caliper to the fork.

Gently remove the little brake pad and set it aside.


Pull back (compress) the caliper bracket, thus pushing the caliper guide pins in as far as possible.

Shift and tilt the big brake pad so it looks like this

Push one edge of the brake pad over the caliper pin allowing you to easily remove the other side shortly thereafter.

Your caliper should now look like this.

Remove the anti-vibration bracket (take note of its orientation).

Remove the ceramic (plastic) inserts inside the caliper pistons.

Pump the brake lever CAREFULLY and GENTLY and work both pistons with your thumbs so that both pistons slowly pop out TOGETHER. About 150ml of brake fluid will spill out, so be prepared with a catch container below your working area.

Remove all FOUR seals inside the caliper. You will want to clean these carefully and very thoroughly. There is a LOT of dirt and god knows what else inside and behind these seals. This is why you should rebuild your caliper from time to time.

Reassemble all seals. Put one side of the seal in first, then work both ways around the rubber rings until they seat completely.

Pull out the caliper bracket assembly (the rubber boots should be worked off the bracket gently). One side of the caliper has a rubber boot which cannot be removed. Do not even try or you will destroy it. Clean it in place.

Clean and then lubricate the pins generously.

Spray tons of brake cleaner into the two caliper pin guide holes and make sure you get all of the old crud out. Then, insert a bunch of grease with your finger. The aftermath should look like so.

Lubricate and insert the clean pistons. Some people say to use brake fluid as lube; others use brake lube, as shown.

Push the pistons in with your thumbs until they are flush with the adjacent metal surface.

Insert the plastic (ceramic) inserts.

Install the anti-vibration pad.

Install the big brake pad.

The tabs must face the bottom - not the top - of the brake pad.

This is the incorrect (and opposite) way to install the small brake pad. Don't mess this up!

XXXXXXXXXXXXXX SHOW PICTURE FROM PAD REPLACEMENT ARTICLE. XXXXXXXX

Reinstall the caliper.

Bleed the brakes per the FAQ.


After bleeding, let the bike rest overnight with zip ties installed like so.

Stand on the rear brake while installing these zip ties (this can be a little tricky).

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