Question about 1987 kawasaki GPZ 500 S - GPX 500 R

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On my 1986 GPZ600 the rear brake siezes up when I use it.

The rear brake keeps siezing up when I use it. The pistons do not appear to retract far enough back to allow the pads to be clear of the brake disc.I have taken the caliper off the bike loosened the bleed nipple and had to use a ''G'' clamp to push the brake pistons back into the caliper. Next I thoroughly cleaned off all dirt and corrosion paying attention to the two round steel rods/guides that connect the two halves of the caliper. The rods/guides have been de-rusted and polished up with emery cloth then greased with high melting point grease and have made sure that the brake pads move smoothly on these rods/guides, yet the problem still persists. I cannot think of a reason as to why the brake pistons do not retract back enough after checking the fluid level and the brake hoses are free of any kinks or acute bends. The fluid appears to be getting pumped into the caliper from the brake pedal and slave cylinder but not returning or allowing the calipers to retract when the brake is released. So the problem may be how do I check the brake pistons are able to retract properly and how do I check the slave cylinder ( located near the brake pedal and mounted behind the frame ) is working properly? Thank you for any help or suggestions.

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Sounds like you need to service the caliper. Remove the piston from the caliper by pumping the brake pedal, be warned you will get brake fluid everywhere. Remove piston seals, dust and oil, you'll probably find that the grooves where they usually reside are full of 'crud' thoroughly clean the grooves, clean the seals then inspect seals for damage and replace if necessary, grease seals (high temp grease) and put back into caliper, wipe away excess grease. Inspect piston for corrosion, minor corrosion can be flatted back with 1200 grit sandpaper, if too badly corroded replace. lightly grease piston (high temp grease) and push into caliper. the piston should slide in easily by hand. Finally bleed caliper well, flush new fluid through entire system.

Posted on Mar 24, 2010

Testimonial: "Thanks for that input, I never contemplated about the crud and corrosion affecting the seals and preventing the brake pistons from moving freely. "

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ckoira57

ckoira57

  • 267 Answers

SOURCE: On my 1986 GPZ600 the rear brake siezes up when I use it.

The pistons themselves are generally the problem. The pins and guides just stop the pads from slopping about. Take pads out and caliper off and remove piston and clean out receptable. Check piston seal ring and dust (or packing) ring are not rolled, twisted or damaged. Your pads may even be worn too thin and plunger is having to push piston too far out and ring seals are not sliding on the smoother surface of piston receptable. Hope this helps. Below is a link to a typicall disc brake in exploded view form with part names.
Cheers.

http://www.cmsnl.com/kawasaki-1986-a3-zx550_model12812/partslist/F2294.html

Posted on May 17, 2010

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1 Answer

How to change front brakes


Unbolt the caliper from front forks (2 bolts).
You'll have to move the caliper as far down as the hose will allow to clear the edge of the fender with the caliper to get it off the disc.
Remove the "hair-pin" clip on the one pad bolt, then remove the bolt.
Pop the old pads out of the caliper.
If master cylinder is almost full of brake fluid, siphon some out.
Clean off exposed pistons, then press them back into the caliper.
By hand is preferable, but you might need a "C" clamp to do this.
Install new pads, and reinstall pad pin.
Torque to 75-102 INCH lbs., and install "hair-pin" clip.
Reinstall caliper, and tighten two mounting bolts to 28-38 FOOT lbs.

Because the pistons were pushed back into the caliper (to compensate for the thicker new pads), it'll take several pumps of the brake lever before the pistons move the pads out enough to make contact with the disc.
DO THIS BEFORE RIDING OFF!!!!!!!!
Keep an eye on the master cylinder fluid level (don't let it get so low that air is introduced into the system), and top off with DOT 4 brake fluid.

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How to replace rear brake pads 2002 softtail ?


If present, remove right saddlebag.
Remove the rear master cylinder reservoir cap. As the pistons are pushed back into the caliper, fluid level may rise more than 1/8 in. (3.2 mm). You may have to remove fluid to allow for this.
Loosen, but do not remove, both pad pins (12 pt/0.25 in.).
Pry the inside pad back. Use steady pressure to prevent scoring the brake disc. Pry between the pad and the brake disc in order to push the caliper pistons back into their bores.
Once the pistons have been fully retracted into their bores, pull pad pins part way until the inside pads drop free. Note the pad's original orientation for replacement purposes.
Install pad with two tabs on the inboard side of the rear caliper.
Install new inside brake pad using the same orientation as the pad previously removed. Curved portion of pad must face upward.
Install pad pins until the pins snap into place with an audible click. Do not fully tighten at this time.
Pump brake pedal lever to move inside pistons out until they contact inside brake pads.
Pry the outside pad back. Pry between the pad and the brake disc in order to push the caliper pistons back into their bores.
Verify that inside pads are captured between brake disc and pistons. Completely remove pad pins to free outside brake pad. Note the pad's original orientation for replacement purposes.
Install new outside brake pad using the same orientation as the pad previously removed. If the inside pad moved during the previous step, reinstall. Curved portion of pad must face upward.
Install both pad pins through holes in inner and outer
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1 Answer

Have taken apart but cant get new or old pads back on now. not enough space and part that should move back to make space wont seems to be jammed or siezed. have tried letting out brake fluid but didnt...


  • To install: Front
  1. Compress the piston of the disc brake caliper.
  2. Install the brake pads and caliper assembly.
  3. Lubricate the guide pin. Tighten the guide pin to 16-23 ft. lbs. (22-31 Nm).
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REAR :
  1. Pull out the pad springs and then remove the pads and shims.

To install:

  1. Clean the piston end of the caliper body and the area around the pin holes. Be careful not to get oil on the rotor.
  2. Carefully turn the piston clockwise back into the caliper body (this can be done with a pair of needle nose pliers). Take care not to damage the piston boot.
  3. Coat the pad contact area on the mounting support with a silicone based grease.
A special tool is available to rotate the caliper piston

WARNING

Do not press the piston into the bore as performed on the front disc brakes. Due to the parking brake mechanism, the caliper piston must be turned into the bore.

WARNING

Do not press the piston into the bore as performed on the front disc brakes. Due to the parking brake mechanism, the caliper piston must be turned into the bore.
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Sep 15, 2010 | 1996 Nissan Maxima

1 Answer

On my 1986 GPZ600 the rear brake siezes up when I use it.


The pistons themselves are generally the problem. The pins and guides just stop the pads from slopping about. Take pads out and caliper off and remove piston and clean out receptable. Check piston seal ring and dust (or packing) ring are not rolled, twisted or damaged. Your pads may even be worn too thin and plunger is having to push piston too far out and ring seals are not sliding on the smoother surface of piston receptable. Hope this helps. Below is a link to a typicall disc brake in exploded view form with part names.
Cheers.

http://www.cmsnl.com/kawasaki-1986-a3-zx550_model12812/partslist/F2294.html

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How to replace rear disc pads on t4 transporter.removed caliper and extracted old pads ,caliper piston will not retract so as to allow caliper and new pads to be refitted


this is because these calipers have what they call ratcheting pistons, you must turn the piston and depress it at the same time to draw the piston back inside the housing, there is a specialty tool made especially for these type of brake systems and sears roebuck actually stocks these kits.they run about forty US dolllars.Hope I could help!!!

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3 Answers

How do you retract the caliper to change the brake


Dioes the calipper have any indentiontions? some calippers screw back into place where as some have to be squeezed back into place, also you have to remove the cap from the brake fluid bottle!!! while you are pushing the cylinder back into the calipper.

If its not going back at all then get some wd40 and spray all around the seal trying to get as much wd40 down the fine gap into the sleeve of the cylinder calipper lining. keep doing this and leave it over night use the whole can if you have to. if still no joy then the caliper is siezed and will need to be replaced. bear in mind some do screw counter and anti clockwise. I am not familiar with this model though.
regards
dan

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How do you repair rear brakes on 95 olds cutlass supreme.I can not push piston back far enough to get the pads in.


The pistons in these calipers must be rotated as they are threaded back into the caliper body to make them retract.

You will see two small notches in the face of the piston, this is for the tool to rotate it back. This tool cost about $8 at any parts house and fits on the end of your 3/8 extension, it fits several different makes of calipers (looks like a small box with pins on it).

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rate as fixya if this is what you need. Thanks

  1. Remove the rear disc brake caliper (2K327).
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  3. Lift the rear disc brake caliper off the rear disc brake caliper anchor plate (2B582).
  1. sya~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pads.
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