EMERGENCY BRAKE PROBLEM


Information and questions on GL1500 Goldwings (1988-2000)
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DenverWinger
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Re: EMERGENCY BRAKE PROBLEM

Post by DenverWinger »



If I'm not mistaken it's possible to put the caliper piston seal on "backward".

Although the seal is square in cross-section If you lay the seal on a flat surface you'll see than one edge of the seal has a very slightly larger O.D than the other edge. I think the larger ID is supposed to to the "inward" side of the piston.

I checked the service manual.... It doesn't say anything about this, though.


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4given
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Re: EMERGENCY BRAKE PROBLEM

Post by 4given »

DenverWinger wrote: Fri Jan 01, 2021 10:21 pm If I'm not mistaken it's possible to put the caliper piston seal on "backward".

Although the seal is square in cross-section If you lay the seal on a flat surface you'll see than one edge of the seal has a very slightly larger O.D than the other edge. I think the larger ID is supposed to to the "inward" side of the piston.

I checked the service manual.... It doesn't say anything about this, though.
[/quote

That makes sense Denver. Since you would want the OD side to face the fluid pressure.
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Swagonmaster
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Re: EMERGENCY BRAKE PROBLEM

Post by Swagonmaster »

Typically they will use a square seal ring and just machine the groove at a slight angle that will make the inside of the seal ring ride high and give the seal. You can look but I think you will find that the seal is really square.
Check it by installing the seal ring one way and see how it fits in the bore then take it out and turn it around and see if is sits any differently. The inside edge should be sticking out of the groove just a little and the front edge should feel
almost flush.
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CrystalPistol
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Re: EMERGENCY BRAKE PROBLEM

Post by CrystalPistol »

Swagonmaster wrote: Fri Jan 01, 2021 1:25 pm I have used a grease gun as a last resort before and it does work but just realize that ALL of the grease MUST be cleaned out afterward or o ring damage/brake fluid contamination will result. Rubber (that is not designed for it) and brake fluid really don't do well with any petroleum product.
One is putting in new O-ring seals anyway. I'm sure the bleeder was removed too, likely in a jar soaking. A caliper is just a cast metal chunk with piston cavity and a hole for the bleeder and another for the brake line feeding it. I'm guessing one will clean the caliper body in any event with solvent and brush, followed by little air and it's ready to have the piston and new seal put in. There less chance of injury by a fast piston "pop out" event as often happens with high pressure air. I use brake fluid for lubing seals, etc.

I usually try air first myself, but I sub a wood block wrapped with a rag in the pad area to catch the piston, I've seen a guy try to stop it with his hand alone, he didn't loose too much blood and no fingers were missing, but I know it hurt.
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zeoran
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Re: EMERGENCY BRAKE PROBLEM

Post by zeoran »

It's going to come down to having to push the pistons out, drain the system, pull it off the bike and basically re-do all of the work I just did to "rebuild" it in the first place. My intention was to make it work better and instead it's not working at all. I only used brake fluid to coat the parts but I did coat them all liberally and the pistons went in smoothly and easily. I've got my work cut out for me this weekend. (again)

God bless,

~Mark
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4given
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Re: EMERGENCY BRAKE PROBLEM

Post by 4given »

Inspect o rings very carefully for damage and orientation when you get it apart.
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Swagonmaster
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Re: EMERGENCY BRAKE PROBLEM

Post by Swagonmaster »

After you get the caliper off and before you take the brake hose off put a small piece of wood in between the caliper pistons to prevent them from coming out and apply the brake to try to see where your leak is. Believe me there is nothing worse than going into something a second time and when you take it apart you can't find anything wrong, at least this way there is some idea where to look for an issue. It's possible misassembly is the problem (it happens even to the pros every once in a while) in which case identifying the offending piece may or may not be obvious. Make sure that the square seal ring is laying down flat, that there are not any scratches or cracks in the piston and that the hose seal rings are in place and not leaking and if you split the halves of the caliper make sure the o rings are in place and not damaged and the screws are tight.
Since brake fluid everywhere is not a good idea make sure to pour some water on any leaks after everything is sealed up and installed.
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MikeB
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Re: EMERGENCY BRAKE PROBLEM

Post by MikeB »

zeoran wrote: Tue Jan 05, 2021 10:57 am It's going to come down to having to push the pistons out, drain the system, pull it off the bike and basically re-do all of the work I just did to "rebuild" it in the first place. My intention was to make it work better and instead it's not working at all. I only used brake fluid to coat the parts but I did coat them all liberally and the pistons went in smoothly and easily. I've got my work cut out for me this weekend. (again)

God bless,

~Mark
I am curious how you are doing with your brake project. Are you getting it sorted out?
MikeB
1998 - GL1500 w/184,500 miles ~ 2017 - GL1800 w/13000 miles
USAF Avionics Communications Tech - 1968 - 1986 / Flight Engineer C-130E - C-141B - 1986 - 1992. Retired
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MikeB
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Re: EMERGENCY BRAKE PROBLEM

Post by MikeB »

So how's it going Mark. All good now I hope.
MikeB
1998 - GL1500 w/184,500 miles ~ 2017 - GL1800 w/13000 miles
USAF Avionics Communications Tech - 1968 - 1986 / Flight Engineer C-130E - C-141B - 1986 - 1992. Retired
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zeoran
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Re: EMERGENCY BRAKE PROBLEM

Post by zeoran »

Sorry for the late reply... things have been.... chaotic.

I was able to finally re-rebuild the caliper and the seals held this time. I bled the system a few times, including using a new pneumatic bleeder kit. This did make a marked difference in the braking power. It's still not what I would consider to be 'good' braking, so I'm thinking that either the master cylinder seal has to be replaced as well or maybe I just need a brand new caliper period. I did change the pads while I was at it, although the old ones weren't worn.

One big question I have though. I'm now thinking about doing the other side, especially since I have a braided steel hose line to replace on that side too. But the caliper rebuild kit that I got that is supposed to be good for both front calipers, the other set of seals in the kit are ***NOT*** the same size as the ones I used in the right-front caliper. Is that proper? Are the seals in the front-left and the front-right calipers DIFFERENT sizes?

God bless,

~Mark
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bellboy40
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Re: EMERGENCY BRAKE PROBLEM

Post by bellboy40 »

That is right. The right side caliper piston a little larger than the left side.
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MikeB
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Re: EMERGENCY BRAKE PROBLEM

Post by MikeB »

Front Left Caliper Rebuild Kit From Amazon
https://www.amazon.com/0106-046-Caliper ... +Aspencade


Front Right Caliper rebuild Kit From Amazon
https://www.amazon.com/0106-010-Caliper ... +Aspencade




MikeB
1998 - GL1500 w/184,500 miles ~ 2017 - GL1800 w/13000 miles
USAF Avionics Communications Tech - 1968 - 1986 / Flight Engineer C-130E - C-141B - 1986 - 1992. Retired
Industrial Maintenance Tech - 1992 - 2014
Retired in Tacoma, WA
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