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Old 02-12-2013, 10:02 PM   #6841
Captain115
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Joined: Jun 2012
Location: Brisbane, Straya
Oddometer: 278
Hi everyone, I'm back.

So since last time I posted I have completed disassembled the front brake system. Cleaned all the brown gunk out of the master cylinder, took the master cyclinder piston and spring out and inspected the seals/cups (looked fine).

lso tried to clean the holes in the reservoir, which is where I encountered a problem, namely the needle I was using to clear the hole snapped while in it. Yes, it sucked as there was almost nothing to grab onto to pull it out yet it stuck through into the master cylinder so I couldn't put the spring and piston back in.

Went and got some tiny drill bits (less than 1mm) and drilled it through which seemed to work. I read some stuff on the net that says that it was ok to do, whether that is true I'm not sure? Anyway, seemed to be fine so I connect the MC back to the bike, hooked up the brake hose and caliper, bled it and tried.

Success! Wheel would freely spin and then stop instantly on application of brakes.

However, after doing this about 4 times, the wheel would spin slower as it got harder and harder to move it. Turns out I still have the same problem as before but this time I have some extra info at least:
  • Master cylinder is clean and fine, holes are clear of debris
  • I lubed the caliper bracket pins because I thought they might be sticking, but didn't seem to help
  • If the caliper is taken off the bike, I can manually push the pistons back in with my thumb, it's not like they are getting stuck
  • Opening the caliper bleeder valve doesn't appear to release the pressure on the pistons. Fluid comes out but the wheel stays fairly stuck still.
  • Remember I have taken the dust seals out as I was going to replace them, so they can;'t be causing the pistons to bind

So the pistons just don't seem to be returning back after the brake is released. I assume it is not the MC as the holes are clear, and not the brake line as the pistons don't release even if the bleeder valve on the caliper is opened. I just don;'t understand why I can push the pistons back with my thumb, but they don';t seem to when on the disc.

Thanks

John
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Old 02-12-2013, 10:10 PM   #6842
elsalvadorklr
southern xr rider
 
Joined: Nov 2008
Location: Columbus, GA
Oddometer: 4,149
captain I repeat replace inner seals

the piston being able to be manually pushed is only half the battle...they need to be able to return to their original position...this is done by the seals angle.

the seals are not flat they are angled so that when you pull the lever on the caliper it pushes the piston outwards BUT its the angle of the seals that RETURN the piston back to its position, along with the release of pressure and consequent sukcing back of the fluid.

old seals will not do this

lastly if you had gunk the seals are more than likely shot.

what you must do is take out seals then manually clean THE GROOVES where the seals sit in..the brake fluid crystalizes and pushes against the seals making the pistons hard to operate

you can also polish the pistons so they are nice and smooth

good luck
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Old 02-13-2013, 02:23 AM   #6843
Dino3310
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Joined: Oct 2008
Location: waikato gravel and sand
Oddometer: 673
Quote:
Originally Posted by elsalvadorklr View Post
little ride today, finally have someone take a pic of me and the bike



brap on fellas, see you around

christian

ya could have at least smiled




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Old 02-13-2013, 03:59 AM   #6844
Royal Club
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Location: The Netherlands
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Quote:
Originally Posted by elsalvadorklr View Post
little ride today, finally have someone take a pic of me and the bike



brap on fellas, see you around

christian


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Old 02-13-2013, 04:05 AM   #6845
Captain115
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Joined: Jun 2012
Location: Brisbane, Straya
Oddometer: 278
Quote:
Originally Posted by elsalvadorklr View Post
captain I repeat replace inner seals

the piston being able to be manually pushed is only half the battle...they need to be able to return to their original position...this is done by the seals angle.

the seals are not flat they are angled so that when you pull the lever on the caliper it pushes the piston outwards BUT its the angle of the seals that RETURN the piston back to its position, along with the release of pressure and consequent sukcing back of the fluid.

old seals will not do this

lastly if you had gunk the seals are more than likely shot.

what you must do is take out seals then manually clean THE GROOVES where the seals sit in..the brake fluid crystalizes and pushes against the seals making the pistons hard to operate

you can also polish the pistons so they are nice and smooth

good luck
Ahhhh I didn't know that about the seal angle helping the piston return. In that case I might as well buck up and buy the seals, give them a go and report back. As I mentioned the MC is in perfect working order now, and the hose should be acceptable so I'd say the pistons seals are all I have left to check. Off to buy some seals.

Thanks,

John
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Old 02-13-2013, 04:37 AM   #6846
Sierra Thumper
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Joined: Oct 2012
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Quote:
Originally Posted by elsalvadorklr View Post
little ride today, finally have someone take a pic of me and the bike



brap on fellas, see you around

christian
Christian you gotta rub in that beautiful beach riding don'tcha
I don't have a beach close by...unless I count riding by Lake Tahoe.....but I have some of the best mountian and desert riding in the U.S.
BTW the XR6 is looking damn good
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Old 02-13-2013, 05:47 AM   #6847
Ivanych
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Location: St. Petersburg. Russia
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Quote:
Originally Posted by elsalvadorklr View Post
little ride today, finally have someone take a pic of me and the bike



brap on fellas, see you around

christian
Here is the beach next to me now


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Old 02-13-2013, 05:59 AM   #6848
Sierra Thumper
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Quote:
Originally Posted by Ivanych View Post
Here is the beach next to me now


Nice
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Old 02-13-2013, 07:55 AM   #6849
brucifer
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Location: Eureka, Ca.
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Quote:
Originally Posted by elsalvadorklr View Post
little ride today, finally have someone take a pic of me and the bike



brap on fellas, see you around

christian
Christian, we need some action shots, man! Lets see some wheelies or something.

Quote:
Originally Posted by Ivanych View Post
Here is the beach next to me now


That's some pretty cold looking sand, Ivan. Looks like you and Royal Club have the same type.
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Old 02-13-2013, 08:02 AM   #6850
elsalvadorklr
southern xr rider
 
Joined: Nov 2008
Location: Columbus, GA
Oddometer: 4,149
Quote:
Originally Posted by Dino3310 View Post
ya could have at least smiled





not good enough for ya? kind of like a salvadorean matt damon reverse smile, as in downwards? jajajajajaja

thats what the wife says, IF I smile my lips go down, WTF?jajajaja

cheers dino
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Old 02-13-2013, 08:04 AM   #6851
elsalvadorklr
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Joined: Nov 2008
Location: Columbus, GA
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Quote:
Originally Posted by Royal Club View Post


BEST POST EVER AND YES I left the pictures so it can rub in!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!:ro fl
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Old 02-13-2013, 08:04 AM   #6852
mcma111
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Quote:
Originally Posted by Ivanych View Post
Here is the beach next to me now


Sand??? How about snow!
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Old 02-13-2013, 08:09 AM   #6853
elsalvadorklr
southern xr rider
 
Joined: Nov 2008
Location: Columbus, GA
Oddometer: 4,149
Quote:
Originally Posted by Sierra Thumper View Post
Christian you gotta rub in that beautiful beach riding don'tcha
I don't have a beach close by...unless I count riding by Lake Tahoe.....but I have some of the best mountian and desert riding in the U.S.
BTW the XR6 is looking damn good
sierra when I was a kid or younger around 17,18 or so I used to mountainbike race in your area...in the 90s tahoe and big bear where the places to be! Before and after that I raced in el salvador...jungle and coffee plantations!

good stuff

you guys need to ride down here so we can have some beers and ride around...

thanks, btw... the bike is always an ongoing project...its part of my life...jajaja I rescued it from BOXES completely blown apart...thanks to steve and many many many others here it started for the first time in like 10 years about 3 years ago...then some rebuilds, some mods, a crash that almost totaled it and then well, some good mods again! you know how a bike should progress over its lifetime!

TASTEFULLY

cheers bud
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Old 02-13-2013, 08:12 AM   #6854
elsalvadorklr
southern xr rider
 
Joined: Nov 2008
Location: Columbus, GA
Oddometer: 4,149
Quote:
Originally Posted by brucifer View Post
Christian, we need some action shots, man! Lets see some wheelies or something.


That's some pretty cold looking sand, Ivan. Looks like you and Royal Club have the same type.
Bruce I wish! I always ride alone...maybe its the reason I have a hard time sometimes comunicating with HUMANS!

jajaja

joking aside...if I do get a bud to ride with Ill try...

BTW I suck at wheelies...my thing is riding 2 lane trails FAST...bed of rocks hit the throttle and fly over it...stuff like that, everyone has their niche...that and beach riding and going trough little estuaries is what its all about down here...

btw I hate enduro...99% of people ride that down here...
just goes to show...we are all different...

Ill see if I can get some pics...jejejeje

christian
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Old 02-13-2013, 08:14 AM   #6855
elsalvadorklr
southern xr rider
 
Joined: Nov 2008
Location: Columbus, GA
Oddometer: 4,149
Quote:
Originally Posted by mcma111 View Post
sand??? How about snow!
very niiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii iice
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