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Crabby's Build

Discussion in 'The Garage' started by CrabbyCustoms, Jan 7, 2020.

  1. CrabbyCustoms

    CrabbyCustoms XS650 Enthusiast XS650.com Supporter

    That's a good idea, I will try it.
     
    Jim likes this.
  2. Team Junk

    Team Junk XS650 Junkie XS650.com Supporter Top Contributor

    Watch out. The piston will shoot out with quite a lot force. There are threads here about the process. Looks like everything is cleaning up nicely.
     
    Jim and CrabbyCustoms like this.
  3. AndersJ

    AndersJ XS650 Enthusiast

    +1.Ive removed a piston with compressed air, and I can really recommend it unless you have an empty field you can point it towards. That piston missed every bike in my garage, but managed to hit about a dozen other things...never found it.
     
    Jim, Machine, Raymond and 3 others like this.
  4. Machine

    Machine Race the wind Top Contributor

    A rag, spray lube and a bicycle tire pump has not failed me yet. Easy does it
    ;)
     
    AndersJ and Jim like this.
  5. Jim

    Jim Beyond the edge is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Wrap it up in some rags before you put the air to it.
     
    AndersJ and GLJ like this.
  6. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi Crabby,
    don't use air, it ain't safe. when the piston flies out you have made an air cannon.
    What I do is swap the bleed nipple for a grease nipple and pump the piston out with a grease gun.
    Note that shop air is ~120 psi max where an el-cheapo lever action grease gun exceeds 1,000 psi
    and grease don't have stored energy to act as a propellant.
     
    59Tebo and GLJ like this.
  7. Jim

    Jim Beyond the edge is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    When I was a wee lad, our shop teacher showed us how to make an air cannon. He then demonstrated the correct method of wrapping the caliper in shop rags. In 50+ yrs I've never launched one.
     
  8. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi Jim,
    did your Guru have a fix for when 120psi shop air pressure wouldn't shift it? Besides a 1,000+ psi grease gun, that is?
     
  9. GLJ

    GLJ Never go faster than your guardian angle can fly. Top Contributor

    I have used air with a c-clamp to keep the piston from flying out.
    [​IMG]
     
    Jim likes this.
  10. Jim

    Jim Beyond the edge is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Nope, if the air didn't move it, grease gun was step 2.
     
  11. rsor

    rsor Wanna do this again!

    I would try the air method, I found you need to get it moving a little first with the air, then back in with a C clamp, keep working at it, when it moves a little more, then heavey on the air. But yes keep the C clamp in, maybe try the rag wrapping, I put something heavier over top while it was laying on the floor. It will be a projectile without some form of precaution, that's for sure.
     
    GLJ likes this.
  12. CrabbyCustoms

    CrabbyCustoms XS650 Enthusiast XS650.com Supporter

    Thanks to everyone for chiming in. I started with air but it was too stuck so moved on to the grease gun and it worked perfectly.
    Screen Shot 2020-02-24 at 5.17.37 PM.png February 24, 2020-41-2.jpg
    I cleaned the caliper and stripped the paint, the inside of the caliper has a bit of corrosion but I'm assuming it's still good to use. The piston has a fair amount of pitting and i'm assuming I need a new piston.
    February 24, 2020-44.jpg February 24, 2020-40.jpg February 24, 2020-41.jpg February 24, 2020-45.jpg
     
    Raymond, Team Junk, Jim and 2 others like this.
  13. 59Tebo

    59Tebo 59Tebo Top Contributor

    You assume correctly Crabby! And congratulations on your success! :thumbsup: Hopefully the cylinder inside the caliper can be salvaged with a simple honing. If it takes too much, the new piston may not seal. :( It'll be good as new before you know it! :rock:
     
    Raymond, Jim and CrabbyCustoms like this.
  14. CrabbyCustoms

    CrabbyCustoms XS650 Enthusiast XS650.com Supporter

    Hmmm maybe I need to consider buying a new caliper? since I was buying the piston, rebuild kit and rubber boot anyways, for $40 more I can just get the whole caliper. Probably not worth the risk. Thanks!
     
    Jim likes this.
  15. 59Tebo

    59Tebo 59Tebo Top Contributor

    I didn't intend to convince you to spend more than you have to. But, years ago, I had a truck that started leaking out the bottom of the steering box. I asked my mechanic to quote me to rebuild it with a new seal. A whole new steering box was another $40-50.00. I'll give you three guesses what I chose to do (and the first two don't count!). The ability to turn (and stop!) is important, so chose wisely!
     
    Raymond and Jim like this.
  16. CrabbyCustoms

    CrabbyCustoms XS650 Enthusiast XS650.com Supporter

    Absolutely! easy decision. I just wish I hadn't spent the whole day restoring it!o_O
     
    Raymond and Jim like this.
  17. Jim

    Jim Beyond the edge is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Since the seal is inside the caliper and not on the piston, a little pitting in the cylinder won't hurt anything.... quiet a bit of pitting is acceptable actually. It's the piston that won't tolerate much pitting, as the seal slides against it. I'd stick with the housing you have... if it were me.
     
    Raymond, GLJ, 59Tebo and 2 others like this.
  18. 59Tebo

    59Tebo 59Tebo Top Contributor

    Thanks Jim! Well there ya go Crabby! $40.00 to spend elsewhere!
     
    CrabbyCustoms, Raymond and Jim like this.
  19. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi Jim,
    thing is, there's two of them. Seals, that is.
    The square O-ring on the piston and the seal ring in the cylinder.
    Each one needs a reasonably good surface to run against.
    OTOH, it's amazing how well a less than perfect surface will work.
    Me, I'd use it too but I'd check it really well before I road tested it.
     
    59Tebo and CrabbyCustoms like this.
  20. Jim

    Jim Beyond the edge is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Dunno Fred... all 3 of mine had just the square one in the caliper and a dust seal and snap ring on the outside. None of 'em had a groove on the piston for a seal.
     

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