Caliper Piston Issues

[Guest]

Im rebuilding my calipers and master cylinder from the front of my GS1000GL. I got all the parts and seals from Boulevard Suzuki. I put the piston seal in the caliper. But the piston does not push in easily. The seal looks like it fits well. I have to use my compressor to blow the piston back out. Ive tried several different methods but its only me and I have no extra hands right now. How can I get the piston seated with the piston boot on it. I got on the helpful Bikecliff Page and found this http://members.dslextreme.com/users/...-ends.html#A02 . But its not really working for me. Or I misunderstand it. Any ideas? Thanks Ahead!

[tom203]

A third hand would probably just get in your way! I did this last winter, same problem until I used a small 4" clamp (see attached pic) to hold boot in place until piston got pushed in . BUT my brain currently ain't recalling why it worked! I'm sure someone will appear shortly to offer something constructive.

[hampshirehog]

Pop the boot on the piston as in the photo then fit the boot in the caliper and then push the piston in to the caliper.

[Agemax]

make sure the groove in the caliper that the piston seal sits in is SPOTLESS. clean out any dirt and oxidisation in there. lubricate the seal with brake fluid.
try putting the boot on the piston before sliding it in then just before it hits home, locate it into the groove in the caliper

[gs1000emt]

Thanks for the pic hampshirehog. Your guys ideas def help. Im going to give this a shot when I get the kids to bed. Is it normal to have to grab the piston with pliers (and a rag of course) to turn it in the caliper? I cleaned the groove the seal sits in pretty well.

[Agemax]

just make sure it is all spotless. you should be able to push the piston in just by using your thumbs, it will be slightly harder to pull it out due to lack of grip. pliers should pull it out fairly easily.
lube everything with brake fluid

[eil]

I did my front calipers on Saturday and it took me quite some time to figure out how to get the boots on properly. hamshirehog's picture illustrates the method perfectly.

After the seal and dust boot were in place, the pistons wouldn't go into the caliper easily for me. I found a piece of aluminum and used that to press the piston onto the oil seal and into the bore using both hands. Without something to guide the piston in fairly straight, it can tilt sidewise and bind in the seal before it gets all the way in. (And yes, lots of brake fluid!)

[gs1000emt]

Awesome!!!! Worked like a charm! Had them on in less than 5 minutes. Thanks a lot guys for the input. Now onto the master cylinder plunger install. Any tips or tricks to get that in with the dreaded c clip from hell?

[Agemax]

Awesome!!!! Worked like a charm! Had them on in less than 5 minutes. Thanks a lot guys for the input. Now onto the master cylinder plunger install. Any tips or tricks to get that in with the dreaded c clip from hell?

same advice as before really, just make sure the m/c is spotless clean inside

[eil]

I have the same master cylinder and just did this recently.

If it's really dirty in there, you may have to spend some time cleaning it out. I'm partial to simple green to wash out most of the grease and brake fluid out and then vinegar (which has to sit awhile) to de-rust things.

If it's clean(ish), can you see the holes on the c-clip? If not, then there's a little round clip and plastic washer that may be in your way. I believe these were part of the old dust boot. Pry them out with something angled and sharp, like a scriber. In my case, I was able to mangle and pull out the plastic washer, and then the c-clip came with it.

Ordinary snap-ring pliers may not be able to reach the c-clip. I had a pair of rather small needle-nose pliers that worked okay, although they were a pain for the reassembly.

[gs1000emt]

Yeah I tore it apart a while back. Put it in chem dip and cleaned out with carb cleaner and a copper brush. Seems pretty clean. Cant really remember where the c clip goes and the order for the plunger parts.

[eil]

This is my old MC guts, I took the picture to remind me of the order or assembly.

The banjo bolt side is on the left, and the handle side is on the right.

Ignore the two items on the very right and replace them with the new dust boot instead.

See the rubber seal between the spring and the piston? The knob in the middle goes into the hole in the spring.

[gs1000emt]

Got it! Thanks! Got it all put together now bench bleeding MC. My caliper bolts are not lining up well. I pulled out guide pins and relubed them and put new boots on but its not lining up. Its so close you cant even tell with your eye but the bolts just want to strip and not take. Arrrgghhh! Figured puting the calipers on would be the easy task.

[gs1000emt]

Got the calipers on! Now to mount the master and the lines and then its bleed time. I dont have a pitol grip vacuum pump. I can just squeeze and release bleeder the old fashioned way Right???

[Agemax]

Got the calipers on! Now to mount the master and the lines and then its bleed time. I dont have a pitol grip vacuum pump. I can just squeeze and release bleeder the old fashioned way Right???

yep....go for it. get all that nasty air out the system