Fitting FZ1000 Caliper to FZS600

[sinto607276]

Every home mechanic needs one of these!!!

http://www.ebay.co.uk/itm/BRAKE-DISC-PIS...3f37f03925

Looks a good bit of kit, but I just use two small bits of wood or plastic, and a screwdriver or such to push them back in.

[riedrider]

I got this one:
https://www.louis.de/en/artikel/rothewal...r=10003009
A little bit more expensive but it works fine and I bought it during a 20% off sales promotion 

[sinto607276]

Easy to use as well, save my wee knuckles next time me thinks

https://youtu.be/8MZ33PEVeUk

[riedrider]

I think for bikes the blades are to thick. I always use the thin ones of my tool because in most cases the thicker won´t fit.

[anutz]

OK so one pistons i have sorted out - moves fine now and nice and clean, sits flush etc...

the other will not budge a bit, and one strange observation, if i take the bleed nipple out of the side that WILL seat flush, then pump air in it whistles out the nipple...

Do the same on the other side, NOTHING...

Not messing with it anymore, sending it to powerhouse for a service hopefully they can sort it out

[sinto607276]

I think for bikes the blades are to thick. I always use the thin ones of my tool because in most cases the thicker won´t fit.

Your probably right, was just showing the idea really

[sinto607276]

the other will not budge a bit, and one strange observation, if i take the bleed nipple out of the side that WILL seat flush, then pump air in it whistles out the nipple...

Don't understand why your saying 'pump air in'?

Should be brake fluid that's in there

Have you pushed the pistons back far enough to fit over your pads? Then bleed the brakes?

Do the same on the other side, NOTHING...

As above really, I don't understand what your trying to do?

Not messing with it anymore, sending it to powerhouse for a service hopefully they can sort it out

Don't send it yet till you've tried to sort it, will be something simple, take a step back and think it over.

[riedrider]

Do the same on the other side, NOTHING...

Maybe the bleeder hole in the caliper is clogged.

[anutz]

OK so here is what i did ....

Close both bleed nipples...

Use compressed air blown in the brake fluid hole to push out the pistons - piece of material in the disc slot to stop them popping out initially...

Left one moves, right one not a jot of movement...

Left one i can remove and looks fine, and can easily re-seat

Right one just no movement...

I also did a test, open the Left bleed nipple and with the piston ALL the way recessed in air passes to the bleed screw, no such luck on the second piston, no idea what it means....

tried all sorts...

[sinto607276]

OK so here is what i did ....

Close both bleed nipples...

Use compressed air blown in the brake fluid hole to push out the pistons - piece of material in the disc slot to stop them popping out initially...

Left one moves, right one not a jot of movement...

Left one i can remove and looks fine, and can easily re-seat

Right one just no movement...

I also did a test, open the Left bleed nipple and with the piston ALL the way recessed in air passes to the bleed screw, no such luck on the second piston, no idea what it means....

tried all sorts...

So the pistons are dry at the moment?
If so, before you do the air test, the one that moves ok, put a thicker block in there so it's less to move, better still if it can't move,  smaller bit in piston that won't move at the moment, then try the air again.
I'm thinking that the air is only giving good enough pressure to push out one piston, so needs to be directed to one piston only. Can you pull that piston out by hand or turn it at all? Is it free to move I mean?

[anutz]

no luck its stuck.....

[anutz]

going to connect it to the rear line and see if i can use the brake pressure to push it out... :b

[anutz]

PROGRESS....so refitted the brake line to the rear and the pressue pushed out the stuck piston - the dust seal was warped and chewed up but the piston is in good condition and so have ordered a new seal kit to put in.....

As you hinted Sinto not enough pressure from the footbal pump....

Looking promising again - also have some 0.5mm washer to sort the alignemnt out on the caliper as 1.25mm seems to take it too far back to center and offline again...

shall hopefully eventually post final pics etc 

[sinto607276]

PROGRESS....so refitted the brake line to the rear and the pressue pushed out the stuck piston - the dust seal was warped and chewed up but the piston is in good condition and so have ordered a new seal kit to put in.....

Better this than sending it away at more cost

As you hinted Sinto not enough pressure from the footbal pump....

Football pump? No wonder it wasn't moving :lol
But guess it would of moved if the seal was ok

Looking promising again - also have some 0.5mm washer to sort the alignemnt out on the caliper as 1.25mm seems to take it too far back to center and offline again...

shall hopefully eventually post final pics etc 

Hurry up man, we've been waiting on more pics
And your missing riding time :pokefun but then you've still to test it all for its MOT sure it'll sail through with all the foccin work you've done

[anutz]

as a side project i dug out the old caliper - now that i understand more about them i think i can clean it up nicely.....will need re-painting so will post some pics of that as i go....

[anutz]

I wander if anyone can answer my query....all i have left to do it bleed the rear brake....however in thought i would just check the torque on the banjo bolts and it raised a point...

There a "Projections" on the Master Cylinders and Calipers, front and rear, not just specific to this one i am fitting....

In the Service Manuals it highlights the importance of contact being made with these prjections when tightening the banjo bolts...

This is something that is making me have to carefully consider HOW i do this with the bluespot rear i have as the standard hose does not seem to "reach", but i am looking at putting a braided hose  i have on, still i need to know the importance of the "projections"...

Thanks

[riedrider]

The projections should prevent the brake lines from spinning around when you tighten the banjo bolts.
If you can apply the specified torque to the bolts and you can keep the lines in place (maybe with cloth wrapped pliers) everything is fine.

[sinto607276]

My 2p worth
That sounds like it's only to do with the original pipes and not the braided as it's in the manual, they wouldn't be talking about upgrades I wouldn't imagine.

[riedrider]

If you have good braided lines then the fittings are the same like original and the projections should fit.
Here are braided lines from Melvin on my ex-blue spot calipers. The projection is marked with yellow arrow:



Problems might occur if a caliper is from another bike. Then you can use custom made lines with the right fittings for the caliper.
Examples for fittings on page 4:
http://media.melvin.de/Infoseiten/Sonder...lungen.pdf

[anutz]

The difference is slight between the angle of the Banjo insertion on between the Bluespot Rear i have put on versus the OEM caliper....but it IS enough based on what i have been messing with to stop the projection being adhered to..

Will do some more playing tonight and see if it CAN fit correctly....if not may need to contact HEL and ask them for a longer rear hose and also account for the custom caliper i am fitting....

It is not miles off just too tight to be comfortable, and i am not going to force anything when its related to braking...