Front brake system service - Yamaha RD400F

[SoCal250]

I'm in the process of servicing the front brake on my Daytona which was in need of a full teardown as the caliper was dragging badly. So, today's project was "get the stuck piston removed". After removing everything from the bike and breaking everything down, I couldn't get the piston out of the caliper with air. I went up to 75psi and it wasn't budging after it got to a little more than halfway.


I decided to use Ken's (kpke) trick of wedging sockets into the ID of the piston and twisting it out with a ratchet and socket extension, but even that didn't work.


So I went to the method that I used on my TZR last year which takes Ken's trick one step further. I heated up the caliper in the BBQ at 225F for about 20-30 minutes and then melted a couple ice cubes in the ID of the piston. After draining the water out, I then went to Ken's trick and the piston came right out with some easy twisting.  


After several round in the ultrasonic, detailed clean up, and masking, I'm off to the next step tomorrow - paint and then bake in the BBQ.

[dgorms]

Nice Russ, I just stored that trick into my data base.

[1976RD400C]

Looking good. I just did the grease gun method on my RZ calipers. Oh what a mess that makes.