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Thread: Caliper pistons stuck

  1. #1
    Join Date
    Dec 2019
    Location
    Long Island
    --
    85

    Caliper pistons stuck

    So planned to rebuild the front caliper on my '86 350X, but when I tried to remove the seized phenolic pistons, the tops just crumbled off leaving the pistons stuck down in the bore. I tried compressed air with no luck. I then got frustrated and went at it with a and cold chisel thinking I could break up the phenolic material. Well, I got a little of it broken up (that stuff if fu@#ing hard!) but managed to put a bit of a gouge in the bore. Hoping I can get the rest of the pistons out, blast and polish the bore and hope for the best. 86 front calipers are hard to find without spending $$$. So a couple questions.
    1. Any ideas how to get the remnants of the phenolic pistons out without further damaging the bore? I was thinking a media blaster may do the trick and just blast it away? (excellent excuse to purchase a bench top blaster BTW)
    2. If the bore is shot, can I swap to an 85 caliper? If so do I just need the 85 caliper and bracket or are other modifications needed? Thanks!
    In the garage
    2007 Yamaha Tri-Z 450
    2017 YZ 250F
    2003 XR100 (son's)
    2005 Raptor 350 (other son's)


    Gone but not forgotten
    86 350X
    16 WR 250R
    03 FZ1
    96 Katana 600
    89 XT350
    84 250R
    84 200X
    79 ATC 110
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  2. #2
    Join Date
    Jan 2010
    Location
    Sulphur Springs,Texas
    --
    1,005
    Yes an 85 caliper will work. For a stuck piston I pull the pads out and put a c clamp on a piston and pump the brake lever to push the other piston out.
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  3. #3
    Join Date
    Jul 2009
    Location
    South Florida
    --
    6,787
    Another trick is to use a grease gun were the banjo bolt screws in , very effective on seized calipers .
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  4. #4
    Join Date
    Jan 2009
    Location
    ohio
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    1,767
    I second that you will be amazed with the power of hydraulics
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  5. #5
    Join Date
    Dec 2019
    Location
    Long Island
    --
    85
    Thanks guys- Grease gun worked to an extent but they're out. Cleaned the bores out good and the gouge didn't look so bad. I put the new seals and pistons in and I'll see what happens. Worst case scenario is it leaks and I'm back to square one.
    In the garage
    2007 Yamaha Tri-Z 450
    2017 YZ 250F
    2003 XR100 (son's)
    2005 Raptor 350 (other son's)


    Gone but not forgotten
    86 350X
    16 WR 250R
    03 FZ1
    96 Katana 600
    89 XT350
    84 250R
    84 200X
    79 ATC 110
    74 ATC 90

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