caliper piston extractor

[flash2002]

Hi guys, I was working on my 1200 brake caliper and the pistons where stuck I mean really stuck. So I tried to pop them out with air like usual and no luck they where stuck. I decided to make a tool to extract the piston, see pictures. It works great, put the pipe in the piston turn the handle to spread the pipe, when the handle stops turning the piston brakes free and it starts turning and you just pull it out.


Parts I used, 1'' OD steel pipe about 12'' long a 5/16 rod and nuts some of the parts I made my self out of aluminium. On the pipe I cut 5 slots the length of the inside of the piston about 1 1/2'' I broke off 2 tabs so it wont be hard to spread. The aluminium parts I turn with a press drill and files, the handle was drill and tap to 5/16 .

[Fatwing Chris]

Nice work,but it would have been easier and quicker to just unbolt the caliper from the bike,remove the pads and then just pump the brakes.Never seen one stuck bad enough that hydraulic pressure wouldn't spit it out.I've also heard of adapting a grease fitting to the bleeder screw hole and pumping grease into it.but the first would be the preferred method obviously.Glad you were able to get it out.Fabricating tools can be a lot of fun also.

[flash2002]

Nice work,but it would have been easier and quicker to just unbolt the caliper from the bike,remove the pads and then just pump the brakes.Never seen one stuck bad enough that hydraulic pressure wouldn't spit it out.I've also heard of adapting a grease fitting to the bleeder screw hole and pumping grease into it.but the first would be the preferred method obviously.Glad you were able to get it out.Fabricating tools can be a lot of fun also.

Hi Chris, this might be going as a parts bike, so the bike was taken apart and all the oils where out so no hydraulics.

[rzaugg]

I typically will just use a c-clamp and try to squeeze the piston in to break it loose from the seal, then air will get it out. Hasn't failed me yet. If you put one of the pads in between the clamp and the piston, you don't have to worry about damaging the piston lip and you can also use the pad to make sure that the piston doesn't fly across the garage when you apply the air pressure to it

[flash2002]

Hi RZAUGG, I know there are different ways to get them out, but I like making tools for stuff like this, it's a pass time.

[flash2002]

Had to make a new tool for the piston, the front calipers have smaller pistons. The tool is the same except it's 3/4 '' pipe.

[HawkeyeGL1200]

Very creative way to get the stuck caliper pistons out. Nicely done!

[WingAdmin]

Nice work,but it would have been easier and quicker to just unbolt the caliper from the bike,remove the pads and then just pump the brakes.Never seen one stuck bad enough that hydraulic pressure wouldn't spit it out.I've also heard of adapting a grease fitting to the bleeder screw hole and pumping grease into it.but the first would be the preferred method obviously.Glad you were able to get it out.Fabricating tools can be a lot of fun also.

Hi Chris, this might be going as a parts bike, so the bike was taken apart and all the oils where out so no hydraulics.

I've been in that position before as well. I screwed a bolt (not a banjo bolt - but one the same size) into the caliper inlet to seal it off, then put a grease gun onto the bleed nipple. Grease guns can generate tremendous pressure, and when I pumped it up, it pushed the pistons out.

Where your tool would work great is when one piston is already out, and the other is seized solid - there's no decent way (apart from reinstalling the one piston) to get that second piston out.

[flash2002]

Nice work,but it would have been easier and quicker to just unbolt the caliper from the bike,remove the pads and then just pump the brakes.Never seen one stuck bad enough that hydraulic pressure wouldn't spit it out.I've also heard of adapting a grease fitting to the bleeder screw hole and pumping grease into it.but the first would be the preferred method obviously.Glad you were able to get it out.Fabricating tools can be a lot of fun also.

I

I understand what your saying, but this way no air or messy grease, stuck or not they come right out.

Hi Chris, this might be going as a parts bike, so the bike was taken apart and all the oils where out so no hydraulics.

I've been in that position before as well. I screwed a bolt (not a banjo bolt - but one the same size) into the caliper inlet to seal it off, then put a grease gun onto the bleed nipple. Grease guns can generate tremendous pressure, and when I pumped it up, it pushed the pistons out.

Where your tool would work great is when one piston is already out, and the other is seized solid - there's no decent way (apart from reinstalling the one piston) to get that second piston out.