Hi Chuckie,


Tim Davies schrieb:
> ...You will have to drain the brake fluid to relieve the
> pressure to be able to pull out the pistons....
>

I agree with Tim that it is easier to work on the calipers if you have
them on the workbench.

But obviously Timīs method did not work for me ("to have to drain the
brake fluid to relieve the pressure to be able to pull out the pistons")....

My pistons stuck that hard that I was not able to get them out "with a
hammer and vise grip"

To not damage the pistons, I did not dare to work with raw force so I
tried it the gentle way :

While the caliper was already loosend from the fork but still connected
to the brake line, I removed the brake pads and then gently pumped with
the brake lever.
This way the brake fluid pressed the pistons slowly out of the calipers.
As the pistons did not come out simultaneously, I put a thin piece of
plywood in place where the brake pads used to be.
This way the piston that came out first was stopped by the plywood just
one or two millimeters of his way before he would have fallen out of the
caliper (if he would have fallen out, the brake fluid would have escaped
totally from the caliper and therefore there would not have been any
further pressure available to force the second piston out).
When both pistons were stopped by the plywood, I stopped pumping,
wiggled the plywood out and then I pumped the pistons the remaining one
or two millimeters out.
Of course one piston came out while the second was still sticking in the
caliper - but only for one or two millimeters.
Then I used a masking tape to protect the second piston and used a
pliers to wiggle it out.

All other steps of cleaning and reassembling worked for me the same way
that had been already mentioned here....


Hope this is of help, and I wish you good success !


--
Regards,

Wolfgang Kaufmann (Austria/Europe),
iPCRC # 634
in order of purchase :
PC800 `90, "Mazda Baby", 89 K miles (1992)
PC800 `96, still unnamed, 14 K miles (2000)
PC800 `90, "Harlequin", 52 K miles (2002 - completely restored project bike)
new in my stable:
PC800 `96, still unnamed, 9 K miles (2006)
PC800 `89 - nice little miniature (2007) ! (does this count too ??) ;-)
http://tinyurl.com/2fokje
http://www.mtc81.at/pc800.htm (in German language)
http://tinyurl.com/ysqcqp




> On Jan 13, 2009, at 6:09 PM, wcbushey@... wrote:
>
>
>> Do I have to remove the calipers entirely from the bike or can I work
>> on them while they are still attached to hose. Do I drain the calipers
>> before commencing.
>> Chuckie
>>

--
Regards,

Wolfgang Kaufmann (Austria/Europe),
iPCRC # 634
in order of purchase :
PC800 `90, "Mazda Baby", 89 K miles (1992)
PC800 `96, still unnamed, 14 K miles (2000)
PC800 `90, "Harlequin", 52 K miles (2002 - completely restored project bike)
new in my stable:
PC800 `96, still unnamed, 9 K miles (2006)
PC800 `89 - nice little miniature (2007) ! (does this count too ??) ;-)
http://tinyurl.com/2fokje
http://www.mtc81.at/pc800.htm (in German language)
http://tinyurl.com/ysqcqp




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