Front-right brake caliper overhaul #1 (My original blog was written on 4th Jan 2008)

The year was changed and the new year of 2008, from today I started to overhaul the brakes.

After removing the calipers I recognized that 10 years were enough periods to make the calipers terrible.

I was a little worried that the calipers could be revived by the overhaul.

Anyway I started the work. Firstly I wondered how I could remove the caliper pistons because I didn’t have an air compressor. I thought I would go to a gas station to borrow the compressor…

I tried the small air compressor built in the battery booster to remove the piston. Then surprisingly it worked.

(It seemed to be better to put the brake fluid in the caliper to reduce the air. Without the brake fluid the piston could not be removed because the air compressor was not powerful enough.)

I was bit surprised by the brown and dirty pistons. But I was relieved because the dirtiness could be cleaned by rubbing with fingers.

The progress of the work was slow because it was first time for me to overhaul the caliper.

Well, I would do it slowly. ☺︎

Comments

Clutch master cylinder overhaul #2: tough match

I disassembled the removed clutch master cylinder. And I found that the piston was heavily rusted. I tried to hit it with a hummer , Pushed the piston using the vise clamp like this. However , the piston was heavily sticking by rust and it could not to be moved today. The brake master cylinder was replaced in the past , however , the clutch master cylinder was not. Therefore , the condition of the clutch master cylinder might be worse. Tentatively , I would spray the rust-penetration lubricant from both sides of the piston and try again in a few days. If it doesn ’ t work , I would give up the overhaul and order the new part. ( My original blog was written on 2nd July 2009 )

Tip to repair rubber parts

I disassembled the rear axle before. There had been no progress on it because I started the repair of the fuel tank during my summer holiday. While painting the fuel tank , I repaired the torn rubber boot of the parking brake wire. I guessed it didn ’ t cost high because it was small rubber part. But I wanted to try the repair method I read on the magazine article before. This was the condition before the repair. The rubber was torn apart and separated almost. I used this self-adhesive type butyl tape. I pasted lots of small pieces of the butyl tape on the back side of the rubber boot. As time goes by , these tapes would melt and stick together. After this I applied plenty of adhesive “ Super X Black ” on the rubber boot. On the magazine of MOTO MAINTENANCE , I read the article that the motorcycle seat was repaired with this method. So , I wanted to try it. After drying 1 day , it became like this....

Clutch master cylinder overhaul #5

Regarding the clutch master cylinder which I repaired the hole at piston with solder , one of my friend advised me that the solder might not be hard enough. Therefore , I tried the repair again in another way. Disassembled the clutch master cylinder again. Now I can do it very quickly because I disassembled brake master and clutch master cylinders many times J Heated and removed the solder at the piston hole. I used the soldering iron instead of the burner because I heard giving too much heat on piston should be avoided. In this time , according to the advice from my friend , the repair method is to screw in the thread with strong adhesive into the hole , then grind the thread head to make the piston surface flat. In order to do it I bought bolts and a grinding stone at the hardware store. Cutting the bolt to adjust the length to fit the hole depth. Engrave the minus groove at the cut bolt head to make screwing in possible ...

The day my "onboro ALFA" would revive

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