Frozen pistons in XS650 caliper

[Terry]

The story is this, 72 XS650 brake pistons are frozen to calipers. I've soaked them in PB Blaster for days on end, applied heat, bought a piston removal tool and nothing, not a budge, nothing, even tried blowing them out with the air compressor. Frustration, walk away, have a couple of Black Bush's, try again, nothing but more frustration, more Black Bush. Finally, I take the damn thing to the local indie shop and the guy blows one of the two pistons out with grease, one hell of a mess but at least one is free. I didn't see him do this but he told me he blew grease back through the bleeder fitting. I figured I'd try it with the other piston, no go, in fact I can't even get the grease to go in the bleeder fitting. So, the question is this. Do I need to go find a Zerk fitting that will fit into the threads of the bleeder fitting, is there even such a thing????? Or do I have to find a machine shop that will remove it or bite the bullet and find a 77 or later front end for this bike?

Sorry for the long winded explanation, but this is the last thing I have to do to get this bike back on the road. I have lavished time, money and Scotland's best export to rebuild this bitch and I refuse to be defeated!!!!!!! Thnaks for any help.

Terry
J'ville, Fl.

 

[JRK5892]

how much air you running to them? if you have tried soaking them in PB blast and they will not blow out, are you sure they do not screw in?

 

[Qckslvr]

not to hard to do, but I didn't use the bleeder, you can find AN fittings that will screw directly into the banjo bolt. With the AN fitting attached you can then hook up your grease gun.

I also like to soak them for about a week in a coffee can full of diesel first too.

 

[diesel450]

Bushmills is Irish

 

[pawn]

do what qckslvr says, that's how mine were removed when frozen in place for a few years.

 

[Terry]

I tend to go back and forth, Ireland to Scotland.

Terry
J'ville, Fl.

 

[Rocan]

your doing it wrong.

you need the fitting for the grease pump. pump slowly and steadily; trust me it will come out with the kind of force the pump can put out.

its all about making the force equal and covering the whole piston, as well as hydraulic force. two things grease takes care of.

not THAT bad to clean up.

 

[Terry]

Thanks to all!! Success is mine!!! I went up to my local Ace Hardware and got some metric zerk fittings, popped in the opposite piston and used a hose clamp to hold it in while putting the grease into the other side. It finally popped out but it was one of, if not the, dirtiest jobs I've ever done on a motorcycle. It also didn't help that I bumped the grease gun plunger while replacing the tube of grease, thus causing a grease volcano on my workbench, I swear I used every rag in the shop! This is not a job I want to do again anytime soon.

Thanks to all
Terry
J'ville, Fl.