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XT600E frontbrake! XT600E frontbrake!
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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  #1  
Old 17 Jan 2010
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XT600E frontbrake!
Hello,

Really need some advice.

Changing front pads today, all going well until trying to fit new pads and one of the pistons won't budge to make room. Looks like it is not quite straight in the caliper. Has anyone got any ideas how to get it back?

Failing that I would be grateful if anyone has a spare front brake caliper to fit a 2003 XT600E they can sell me.

Thank you,

Biggy
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  #2  
Old 17 Jan 2010
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Is the piston out/almost out?

When I maintained my front brake, I used a pice of cloth, over a socket, put it in the piston, and then...Hammertime

Dont know it this is you're problem tho.
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  #3  
Old 17 Jan 2010
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Put the hammer away, get a g-clamp (woodwork or metalwork) and use that to gently push the piston back into the caliper..
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  #4  
Old 17 Jan 2010
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Thank you
Thanks guys,

Yes I tried the G-Clamp and the hammer and still it won't budge. Are there any other options?
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  #5  
Old 17 Jan 2010
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That sounds bad.....

if you cant get the piston back in with a clamp then you need to take the whole caliper off and get the piston out.

if its that tight it sounds like water has got in behind the seal and the corrosion has increased the pressure on the piston.

to get the pison out i use a electric air pump untill it pops out. carefully!!!!!
take the seals out and clean up the metal behind seal with dremmel
a little grease and put NEW seals in
then pop the piston back in and off you pop.

Ive just done this on the front and rear of my 3yf and the brakes are much better and its not worth the risk having shoddy brakes....

good luck...
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  #6  
Old 17 Jan 2010
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Put the hammer and the dremell away , First clamp the good piston so it cant come out , Then make sure theres plenty of brake fluid in the system and pump the brake lever with all your might , The stuck piston should come out with some force so put a rag around it and a bucket under it .Then clean off any corrosion from the piston and the caliper housing with very fine wet and dry paper . When re:fitting the piston use plenty of brake fluid as a lubricant and dont forget to loosen the bleed nipple so that any air in the caliper can escape . PS DONT use wet and dry on any rubber parts, The seal in the caliper can easily be pulled out and re:fitted when cleaned . Regards, Trev.
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  #7  
Old 17 Jan 2010
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If you get REALLY stuck... If you pay return postage, ill get the piston out using my airline...

Send me some new seals and Ill refit it too !!

I'm feeling generous.... lol
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  #8  
Old 17 Jan 2010
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Exclamation
If you're going to use grease to aid installation of the piston, you cannot use normal grease as it will swell the rubber seals(due to incompatibility with the type of rubber used in brake systems) & cause the piston to bind.
You must use specific "rubber grease"(which is castor based not mineral based) or brake fluid.
If you've used excessive force, e.g. a hammer(which is a no no) the piston may have damaged the seal.
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  #9  
Old 18 Jan 2010
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yep your right about the grease......you should get some with the new seals...mine was orange stuff!

i use a flat brass brush on the dremel as it get into the seal grove and get all the junk out really easily and wont effect any finished surfaces.

good luck
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  #10  
Old 18 Jan 2010
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Thank you
Thanks for all the advice guys.

I was feeling really down yesterday afternoon (particularly as I need my bike for commuting and I was condemned to another day on the trains).

Your collective kindness gave me a real lift and new impetus to get the problem resolved.

Thank you,
Ben
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