Tt600re front brake issues
 

Has anybody out there got a solution to my brake issues for my 2004 TT600RE? The front brake is dragging slightly causing the disc to become hot even when I do not use the brake. I have stripped and cleaned the caliper and seals - the piston action is slightly uneven, but better than it was (and making no difference anyway!). One of the dust seals is slightly damaged bit this is the only obvious fault. The master cylinder is a puddle of rust! Any sensible advice is welcome including any potential alternatives that might fit. I tried a XT600E caliper today - this bleeds ok but does not relieve the sticking brake. I have tried and tried to find service parts for this brake system but nothing is available either from Yamaha or Brembo. I really like the bike (I've owned it for seven years) and we've been on many trips together. I'm due to go to Scotland on it in two days but I'll have to shelve it. Help!!!!

the M/C diameter shoudl be stamped on the casting, 11, 12, 13, etc, i think it's a 12... check


these rebuild kits are readily available in italy....


https://www.ebay.it/itm/BREMBO-KIT-REVISIONE-POMPA-FRENO-MOTO-PS-12-COD-10279720/113781457436

Thanks that's a start, but I notice none of these kits are specific to the TT600RE. Are Brembo master cylinders generic? Also, I need to rebuild the caliper - new seals etc. From my research so far I get the feeling that there is nothing specific out there. Combined with the non-availability of spares makes me wonder if there are other alternatives. For example, a friend of mine has a CBR600 master cylinder fitted to his Japan only XR250S. Also, I notice it may be possible to fit a Magura master cylinder to the TTR - has anyone out there done this?

brembo stuff has been mounted on many makes, no TTRE specific stuff IMHO, dismantle your M/C and youll see if the piston kit looks the same as in pic



I can get all parts for even 70s-80s brembo stuff, all my vintage racers use F05 and F08 calipers, no problem finding kits


try also here,

https://store.bevelheaven.com/Rebuild-Kits-Parts/


my supermoto xt600 wears a GSXR front caliper, so in theory any M/C & caliper cna be adapted, but for the caliper youll need to make your own adaptor paltes... not rocket science by any means

Check out the same era KTM EXC model brake spare parts. They all used same or similar brembo brakes and can use the genuine overhaul kits from KTM. The front calipers actually bolt straight onto the TTR !

Where is that stamp supposed to be and what does it look like?

On these TT600R front calipers for example.

https://i.ebayimg.com/images/g/w9oAA...AY/s-l1600.jpg

https://i.ebayimg.com/images/g/Es4AA...AY/s-l1600.jpg

M/C means Master Cylinder, or in simpler words, the pump, they always have their own diameter stamped on them


You are showing calipers, they never have the diameter stamped on them...

Ok, now I follow you [emoji106]

Hi, everyone. Thanks for all your help so far. To bring you up to date I have managed to purchase a secondhand complete brake system for the mighty TTR. Thank the gods of eBay! The MC works perfectly and is in good condition the calliper, on the other hand, is very, very dirty - that's in a paraffin washer as we speak. I've found new seals and fitted them but the pistons are still a problem. I've ordered some off eBay to the same bore but 32mm long (depth of the calliper is 29mm in case you're wondering). I'm going to have these turned down on a lathe and take it from there. believe me when I say these pistons just are not out there. I did look at KTM pistons but they only give bore sizes or just they are off such and such a KTM. When I've contacted eBay sellers for more information they just don't want to know - they're sellers at the end of the day I guess. As a plan B I need to find a nice, friendly KTM dealer who cares about his or her customers enough to measure some pistons - anyone out there?

The updated update is that I've stripped my eBay calliper after it spent a couple of days in a paraffin bath. The pistons are in good nick so I've fitted them to my original calliper (with the new seals in). It's also got its new spring clip thing in (the one that sits on top of the pads when in situ). It's all fitted together with new metal seals at the banjo joints but it will not bleed!!!!!!! I'll give it a rest for a few days.
My other 28mm pistons have arrived (x 32mm long) and I'll get them turned down to fit the now clean spare calliper, once I've fitted new seals - to be kept as a spare.

bleeding can be a pain in the behind, even when you have a lot of experience,



put some Teflon tape on the bleeding nipple threads and try both sucking liquid form the nipple as well as "reverse bleeding", i.e. pushing liquid (but no bubbles) into the nipple


another trick is to put an elastic band on the brake lever so it's compressed overnight, the bubbles get smaller so have an easier time raising up to the reservoir

Thanks. All of the above tried. It's nearly there!!! Incidentally, I've left off the clip thing (?anti-rattle clip) as it looks like it could catch the pistons - two old clips I have seem to show damage in this respect. The rubber band method seemed to work best in the end. Brake is working really well now but it still doesn't feel spot on.

Just jumping in here regarding the master cylinder overhaul; 91 XT600E. The circlip is deeper than any of my 4 pliers will reach. Which brand / model number of circlip plier will work so I can order one up.
Cheers
Min