(06-06-20, 01:05 AM)Grahamm link Wrote: I spent an entertaining evening learning how to strip down, clean and rebuild the front brake calipers from my FZ6 and then getting a not very nice surprise...

The first problem was that, on one caliper, the smaller of the pistons would come about half way out, then, no matter what I did to block the larger one, the small one simply wouldn't shift any more.

Eventually I used a G Clamp to push it back in, kept the other one completely blocked, put something in the way of the smaller one, but so it would stop further out than it had gone before, then gave it as much pressure as I could from the bike pump I was using and, thankfully, it popped far enough out to get past whatever was making it stick.

I then "walked" them out by putting thinner blocks in front of them until they'd both got past the inner seals and I could just wiggle them out with finger pressure.


So I got everything cleaned up, new seals in place etc and started to reassemble it, but I couldn't get the pads to go back into place.


I know they were stiff when they came out, but I figured that was because they hadn't been cleaned for ages (or at all!) and they were on the sides that originally came from, because I was very careful about that, but I couldn't get them to fit back in place as they kept getting stuck.


Finally I looked up the code on the back of them and found the pads on a Russian website. It also had the details of the dimensions and some pictures of the bikes they were for.


I looked at the pictures. FJR, R6, R1, a 125... FZ6 Fazer? Nope, no FZ6 Fazer...!


So I tried looking up the dimensions for the FZ6's front brake pads...


The sizes of the ones I have are 94.0 x 41.0 x 10.0mm


The FZ6 pads are 93.8 x 40.3 x 9.8mm


So whatever Foccer put the pads on the front brakes, put the wrong damn ones on!!!

:2guns

Ok, they are literally just about 0.2mm too big and they still work because I've been using them for years, but they wouldn't go back easily.


I then spent ages carefully grinding down the ends with a Dremel, shaving a fraction of a mil off, checking the fit, taking another tiny bit off, re-checking, rinse and repeat until they fit properly into the caliper bracket.


Unfortunately I think the place that put the wrong ones on isn't in business any more (they've been on there for a while), so there's no chance of going back and giving them a bollocking

(06-06-20, 10:52 AM)Gnasher link Wrote: [quote author=Dudeofrude link=topic=6412.msg315897#msg315897 date=1591280433]
Good....means I'm not riding like a dick then ??

(06-06-20, 12:46 PM)Dudeofrude link Wrote: Oh dear, you don't have to ride like a dick not to have chicken strips, seems you're somewhat touchy about that  :rolleyes  your get there in time, perhaps.

(06-06-20, 12:59 PM)Gnasher link Wrote: [quote author=Dudeofrude link=topic=6412.msg315945#msg315945 date=1591444018]
Oh dear, you don't have to ride like a dick not to have chicken strips, seems you're somewhat touchy about that  :rolleyes  your get there in time, perhaps.

(06-06-20, 01:37 PM)Gnasher link Wrote: So was mine  different sense of humour, I guess.


WTF Boris has to do with it, you've lost me there  :groan I haven't thought about him for days to be honest, clearly you have.  :rolleyes He does have that effect on some people. 

(06-06-20, 01:37 PM)Gnasher link Wrote: So was mine  different sense of humour, I guess.


WTF Boris has to do with it, you've lost me there  :groan I haven't thought about him for days to be honest

(06-06-20, 01:44 PM)YamFazFan link Wrote: 'for days' :lol . About 10 minutes at best more like :lol

(06-06-20, 10:59 AM)Gnasher link Wrote: Lot more common than you think, pads being the wrong size.  Most are slightly too small which lead to them twisting in the body, after a while they start wearing away the caliper body and then jam, some just jam and the pad wears to a taper. 

Quote:I hope you got all I mean all the crap out of the seal rebates. 

(07-06-20, 12:12 AM)Grahamm link Wrote: There were some bits of crud on the outer edges of the pistons which, despite lots of brake cleaner and scraping with a plastic biro cap, wouldn't shift, but that's outside the bores anyway, so fortunately wouldn't affect anything.

(07-06-20, 08:19 AM)Dudeofrude link Wrote: You can get this off with a piece of wet and dry. All 8 of mine had a pretty thick line around the rim but managed to get them all back to almost new.
I used a bit of 1500 wet & dry then polished them up after with some metal polish and a soft cloth to make sure they were nice a smooth
Tedious work but worth it

(07-06-20, 09:47 AM)Gnasher link Wrote: [quote author=Dudeofrude link=topic=6412.msg315980#msg315980 date=1591514344]

You can get this off with a piece of wet and dry. All 8 of mine had a pretty thick line around the rim but managed to get them all back to almost new.
I used a bit of 1500 wet & dry then polished them up after with some metal polish and a soft cloth to make sure they were nice a smooth
Tedious work but worth it

(07-06-20, 08:19 AM)Dudeofrude link Wrote: [quote author=Grahamm link=topic=6412.msg315977#msg315977 date=1591485124]
There were some bits of crud on the outer edges of the pistons which, despite lots of brake cleaner and scraping with a plastic biro cap, wouldn't shift, but that's outside the bores anyway, so fortunately wouldn't affect anything.

(07-06-20, 11:14 AM)Gnasher link Wrote: Next time you, clean off the baked on dust as you call it, put the piston under a strong magnifying lens.  What you'll find is a tiny pit in the cadmium, the dust is clinging to corrosion, as the coating is damaged.