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Post by aerologic on Dec 26, 2008 11:39:43 GMT -5
Hello all,
I'm rebuilding the front brakes this weekend on the RE-5. I have the rebuild kits for the master and 2 calipers. I never knew brake fluid could congeal like this. Yuck!! A couple of questions:
1) Is there a good solvent for cleaning brake lines of this mess? Just use clean new brake fluid?
2) What's a good way to get the big caliper piston out? I'm thinking about drilling a hole and threading it. I've had it soaking in Liquid Wrench for a couple of days to no avail. I've heard about pumping grease into the caliper under pretty good pressure but I'm not setup to do that...unless I have to.
It is supposed to be near 70 degrees in Cincinnati on Saturday. I may get the CBX out!!!
Thanks!
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Post by aerologic on Dec 26, 2008 12:40:46 GMT -5
OK. I got the piston out. Followup questions
1) I still have the question as to what a good solvent is to clean the lines, etc.
2) On mine looks like there are THREE little O rings on each hex bolt but the rebuild kit only has 4 total, so 2 for each hex bolt. Looking at RE-5 parts catalog it does look like 2 little O rings goes on each hex bolt. The picture of the hex bolt in the parts catalog DOES show three grooves though. Where do the O rings go?
3) Assuming the big seal is NOT in place, how snug should the piston be? I know this is hard to quantify. It's pretty darn snug now but with some steel wool I can probably clean up the caliper to make the piston move easier.
Thanks!
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Post by tom93gts on Dec 27, 2008 11:11:49 GMT -5
Not sure on a good solvent, but my lines were completely dried out and the fluid was solid in them. I removed the center wire from a piece of coax cable and shoved it through. Then I washed them inside and out with simple green and water. That worked quite well.
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Post by aerologic on Dec 27, 2008 11:19:13 GMT -5
Thanks. I actually think my lines are clear, nothing solid in there so I will just force some brake fluid through it.
My biggest question is the small O rings. I see in the diagram that there are 2 O rings per hex bolt but there are three grooves. There are 3 little O rings per hex bolt in hy calipers now so I don't know which groove should not have an O ring.
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Post by aerologic on Dec 27, 2008 13:23:49 GMT -5
Jeesh! I bought a circlip pliers at Harbor Freight this morning to get that circlip out of the master cylinder. The "fingers" are too fat!! I need a smaller circlip pliers!
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Post by suzsmokeyallan on Jan 3, 2009 9:52:08 GMT -5
Well maybe i can help you here,,
1 The small o-rings go onto the hex bolts, there are depressions on them but you'll see some are deeper than others so place the two o rings onto the deeper ones. The other depressions in the bolt holds the lips of the boots in place so its not for an o-ring. Dont forget to add grease to the sections inside the boots AND between the o-rings.
2 The piston should drop in with a hair of play when the caliper is empty of its seal and dust boot. To remove the piston, use a compressed air gun fitting into the brake line fitting with a rubber tipped nozzle for sealing it. Hold it downwards in your hand covered with a rag to prevent it blowing out and hitting you. BE CAREFUL,,,,,,70PSI is usually good enough pressure for stuck pistons.
3 Forget the old master cylinder circlip, bend the eyed ends inwards and lift it out, you'll be discarding it anyways. The piston has a spring behind it so be careful not to look into the area like youre checking for microbes as you may lose your eye.
4 As for brake lines if you think youre saying money forget it, once you can see any cracks in the lines surface if you bend it slightly, REPLACE them. If youre not sure they are four years old or newer REPLACE them. They are available form Suzuki still, use the GT 750 part numbers...and the price isnt expensive.
PM me if you need more info,,,,, ill be glad to help.
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Post by aerologic on Jan 3, 2009 10:10:56 GMT -5
Thanks suzsmokeyallan,
The front brake lines on mine are all metal, no rubber lines. I guess they were replaced by somebody along the way. I've run some fresh brake fluid through and I think they are pretty clean now. I haven't reassembled the calipoers or master cylinder yet. I'm waiting for the new pads to come (old pads were not too bad but I thought I'd put new on anyway) and to get the wheels back from new tires. Heck. It's too cold to ride anyway!
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Post by suzsmokeyallan on Jan 3, 2009 12:40:47 GMT -5
Ok fair enough, sounds like youre close to finishing up the work, but stainless braided lines do suffer from age too, the problem is you cant see the cracks because the stainless sheathing is covering it so be wary of just how good they really are. For assembling the master cylinder you can easily fit in the parts (coated in brake fluid) and then place the circlip just inside the body fitting. Then you can press it in by hand with a suitable tube thats the correct size till it sits down in the groove, no need for a pliers if you do it this way. Dont forget to buy a simple vacuum bleeder to pull the fluid down if you dont have one already, it will save you lots of time and you wont have to do any pumping ritual.
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Post by Jess on Jan 13, 2009 23:27:58 GMT -5
I use a mityvac... They work great ;D
Best,
Jess
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Post by aerologic on Jan 31, 2009 13:18:12 GMT -5
I'm back working on the RE-5 after a bout with pneumonia. Yuck! So, I have rebuilt the front calipers. No biggie. I'm starting on the master cylinder and I can't get that recessed circlip out. I bought some circlip pliers at Harbor Freight but they are too big. This circlip is just too far recessed to use a sharp nail or ice pick like tool. Off to Sears Hardware. Online they seemingly have a bunch of circlip pliars but I don't know about a store...
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Post by suzsmokeyallan on Jan 31, 2009 19:26:18 GMT -5
Sorry to hear about your sickness, but youre back to it now so heres what to do,,, place a union bolt into the master cylinder outlet, tighten it, and stand the cylinder up in a vise held by the bolt. Press the piston down and while holding it there use an icepick with a sturdy handle to pry the eyes, one at a time inwards towards the piston. This then collapses the clip and it will soon come out once you invert the cylinder and align it so its free of the lip. I have NEVER found a decent cir clip pliers that can get down in there and still allow you to see what the heck youre doing. Good thing its going in with a new circlip so follow my guidlines in a previous post for installation using the suitably sized tube technique to push it down into the groove.
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Post by aerologic on Feb 5, 2009 9:01:11 GMT -5
I'm good. Thanks to all that helped...
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Post by aerologic on Feb 20, 2009 9:04:07 GMT -5
I've decided to replace my front brake lines with braided stainless steel. Is this something I can get locally or do I need to go to Sam??
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Post by Jess on Feb 20, 2009 19:22:33 GMT -5
Dave,
You can get decent braided stainless just about anywhere...
Just make sure you measure twice before you order... (made that mistake myself).
I am not sure if Sam carries braided stainless lines... Never hurts to ask...
Best,
Jess
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Post by deadmeat on Feb 20, 2009 20:36:16 GMT -5
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