Front caliper dust seals

[Paul]

I have two XS1100, one is an RH and the other is a 78 model E, I pulled the three calipers off the E model to go through the brakes as its the bike that needs the most work, its going to be a lot larger project to get on the road as my post about the cases tells some of the problems I have, anyway I pulled calipers and master cylinders off the bike and realise its not worth my time at present to restore them and I was able to get my hands on the blue spots for the front with a master cylinder and lever to match, these will go on with ss lines as I rebuild the bike, as will the rear be replaced with an upgrade as well. Glad you have found a fix, its great when you can move on with confidence. There will always be differences about weather to use the rubber grease or not, each to their own, I do know there is a lot of differing opinions to use of not.

[steveh]

Ok...i bought a seal kit from Brakemasters in the UK. cost more, about $60AUD...for this you got for two calipers, 4 seals, 4 copper washers, 2 bleed nipples and covers and 4 rubber slide boots plus grease.
But the best thing was that the dust seals allowed you to push the piston in relatively easily AND the piston now pulls back off the disc slightly.
The Brakemaster dust seals were about 0.1 or 0.2 mm thinner cross section and were softer.
I went through 8 TRK dust seals...all were almost impossible to get the piston back in, then all were holding the piston to tight and not letting the piston to pull back when the brake was released...leaving pressure on the pads/disc making it hard to turn the wheel easily.
When i removed the piston each time the dust seals were threaded.

Paul i got ripped off! you got 4 containers of grease for one set of seals...i only got one container of grease for 8 seals!

[Paul]

Pretty sure you should not use ANY sort of grease on the brake components, use the brake fluid you will be using in the system.

Totally agree, never use anything internally except brake fluid on the piston and seals. I used the never seize on the pins as on the rear they were pretty corroded where they fit through the caliper body and it was a very thin smear. TRK seal kits though do come with a red rubber type grease, I still have the three containers sitting on my bench.

[Christian Raith]

Pretty sure you should not use ANY sort of grease on the brake components, use the brake fluid you will be using in the system.

[Paul]

I recently replaced the seals on my RH with ones purchased from Wemoto, they were very tight on my bike so I lathered them up with the grease supplied and carefully used a g-clamp to apply a constant pressure making sure they were straight and level.

I also replaced the slide boots and coated the pin with a smear of never seize copper grease, I do know the brakes work fine on my RH, I went through the front and rear, new hel stainless lines, banjo’s fittings pads and seals. I used compressed air to blow the pistons out originally and to ensure they moved within the caliper before reinstalling in my bike, they were tight but work great now, they move away from the disc after pressure is released to allow the wheel to spin. The drill press is a great idea….

[steveh]

I used a drill press to push them in....seems like they shouldn't be that tight.
Did you notice if the caliper piston moves back off the disc a little after you applied the brake?

[Paul]

I recently replaced the seals on my RH with ones purchased from Wemoto, they were very tight on my bike so I lathered them up with the grease supplied and carefully used a g-clamp to apply a constant pressure making sure they were straight and level.

[steveh]

Thanks for the reply Jonesy....its an RH...the dust seals go inside the caliper.
i have tried every lube know to  man...still seems impossible.
i have polished the leading edge of the piston...on another piston i have chamfered the leading edge!
the actual piston seal is fine
conclusion ...wrong dust seals

will let you know when i succeed

[Jonesy :-)]

hang on did you say dust seals? pretty sure they can go on after piston is installed.

[Jonesy :-)]

lubricate with a smear of brake fluid and be vewy careful and take your time.

[steveh]

any ideas about how to get piston back in without damaging new dust seals?
4 down so far
using TRK Braking seals from Wemoto