NC30 caliper overhaul

[Smoky]

just make sure you got all the right tools before you start

from your experience guys, what tools will i need? id rather get them in now than as i go along...

[viper_biker]

just make sure you got all the right tools before you start

from your experience guys, what tools will i need? id rather get them in now than as i go along...

From top to bottom,

Star head for the reservoir cap,
8mm (bleed nipple) 12mm (caliper bolts) 13mm (caliper banjo bolt) sockets/spanners,
Flat head screw-driver for the retaining pin
4mm allen head (I think) to remove the above pin
Finally, 12mm socket for the 4 bolts that hols the calipers together.

Be careful of the little washer when splitting the calipers and replace the crush washers on the banjo bolts and use loads of brake cleaner.

[Drunkn Munky]

just make sure you got all the right tools before you start

from your experience guys, what tools will i need? id rather get them in now than as i go along...

I use one of these to free up and remove pistons http://cgi.ebay.co.uk/Sealey-Ak7112-Dis ... 240%3A1318" onclick="window.open(this.href);return false;
A Mitivac pump, about £40
Plenty of clean rags!!

Drain or pump all the fluid from the calipers and lines
Remove and split calipers
Give them a good scrub
Free up or remove pistons
Replace seals if needed
Push pistons back in lubbed up with a bit of brake fluid
Refit calipers, lines etc
Use the mitivac to draw the brake fluid through the system
Finish off bleeding the conventional way to get the pistons out to the disc and remove any air bubbles

A bleed nipple double banjo comes in handy aswell so you can bleed the M/C end aswell.

good luck

[Smoky]

I use one of these to free up and remove pistons http://cgi.ebay.co.uk/Sealey-Ak7112-Dis" onclick="window.open(this.href);return false; ... 240%3A1318

blimey that thing looks eveil.. the kind of thing you really dont wanna see your dentist holding...
(noob alert) how do you use that then?

A bleed nipple double banjo comes in handy aswell so you can bleed the M/C end aswell.

i have no idea what a double banjo is.. (please forgive me if im being thick...)

ive got the rest of the tools listed (except the pump) so i think ill search the bay for a cheap pair of front calipers- that way ive at least got a bike to ride while i fettle...

thanks for all the help so far guys- id be lost without the forum.

[viper_biker]

I have a Mity-Vac and as good as it is, it's not worth £39 more than these,

[Drunkn Munky]

ok to use that sealey tool you split the calipers and put the tip of the tool inside the piston (it does fit it just a little big in the picture) and turn the handle, it grabs the piston super tight and allows you to free up and remove them. ive removed some seriously seized up pistons with this and cant fault it.

A double banjo bleed nipple is basically a double banjo bolt (which is the bolt that goes through the 2 brake lines and fixes them to the master cylider) with a bleen nipple on the end, not essential but makes life that little bit easier.

Again the pump is not essential unless you dont mind standing there pumping the brake lever for what seems like forever which when you've never bleed brakes before is a bit deflating as it seems like nothings happening.

I wouldnt waste your money on a second set of calipers, spend the money on a set of braided lines if you dont already have some and a new seal set. New seals are expensive and not always needed so if your pistons move freely enough then id be tempted to save my money. If you get that sealey tool just fix it to a piston, twist and pull the piston out slightly and clean the piston with some brake cleaner and a toothbrush (your girlfriends one will be perfect), rub a little brake fulid round the piston and work it in and out. if it feels nice and smooth the id leave the seals. Be carefull not to pull the piston all the way out though as generaly you should replace the seals if you do, but saying that ive reused old seals and they've been fine.

[Drunkn Munky]

I have a Mity-Vac and as good as it is, it's not worth £39 more than these,

Very true. i just find the mitivac easier to live with

[Smoky]

A double banjo bleed nipple is basically a double banjo bolt (which is the bolt that goes through the 2 brake lines and fixes them to the master cylider) with a bleen nipple on the end, not essential but makes life that little bit easier

ah- now i got ya.

and a toothbrush (your girlfriends one will be perfect),

lol dont tell my wife i have a girlfriend- or else i may just find my brake lines "accidentaly" cut lol

i may hopefully be able to pick up a set of calipers for dirt cheap, which means i dont gotta take my baby off the road (cant stand the train)
and to be brutally honest, i know the old "if it aint broke dont fix it" saying works well with honda'd, but it is reaching 19 years old now, and im unsure as to its maintenance history...
id rather put these things right while i can and just enjoy some trouble free miles..

again, thanks for all the help everyone :)

[Sligeach]

along with the toothbrush for getting into the piston seal recess, it can be useful to have one of those pointed scraper things dentists use.
i am luck that my dad does work with lots of hydraulic seals so has a complete set of dentists utensils. the one i am on about is the one with the 90 degree bend in it. i am sure you will be able to improvise tho
http://tbn1.google.com/images?q=tbn:eqc ... ools_2.jpg" onclick="window.open(this.href);return false;

[Morespeedvicar]

Hiya.
Deffo clean the seal recesses, take the seals out remember which way round they were clean degrease the caliper then clean the oxidation out, i used a dremal with a soft wire brush in it. Wash the caliper again. Get some rubber grease (sometimes called rubber lube) from a motor factors. Put some in the grooves and put the seals back in the way they came out.
Clean the pistons and put a smear of grease on them and reassemble.
I found it best to loosen the caliper half bolts while there on the bike, mine were well tight and very corroded, I put some coppergrease on the bolts when i put them back together.
Hope it helps
Cheers
Ian