Caliper removal and overhaul

Each caliper is.mounted by two bolts (alien screws at the rear These are easily undone and removed. If caliper removal is being undertaken to enable some other task to be started then it will be unnecessary to remove the hydraulic pipe; in which case, support the caliper using an elastistrap to something suitable on the rest of the machine so that the pipe is not stretched, once the caliper has been slid off the disc. The front caliper hydraulic pipe is supported to the fork leg by a rubber-in-metal strip which is affixed to the mudguard mounting. For caliper overhaul, because of defective action or weeping piston seals, loosen the hydraulic gland nut at the caliper whilst it is still mounted on the machine; that way you can have proper purchase. Remove the caliper and unscrew the pipe making sure no hydraulic fluid gets on any paint or plastic. Seal off the end of the pipe to stop fluid dripping. Always have some clean rag around to mop up, should leakage occur. Remove the plastic cover and then the pads as described earlier. Clean the caliper thoroughly with methylated spirits. Do not use any other cleaner; even WD40 will rot the seals.

The late type Laverda rear drum which is effective . The front hydraulic pipe set-up on the Marzocchi identical to that used on the front forked Triple. All other disc braked machines are similar. Note the hose cushioned holder to the left of the fork leg

The late type Laverda rear drum which is effective . The front hydraulic pipe set-up on the Marzocchi identical to that used on the front forked Triple. All other disc braked machines are similar. Note the hose cushioned holder to the left of the fork leg

Meths evaporates!

To dismantle the caliper, place it in a soft-jawed vice (wooden jaws are best) and remove the two alien screws which retain the caliper halves.. Take out the dust seal around the piston and pull out the piston and then its inner seal. Do this for both halves and then clean the whole unit again. Check the pistons and cylinders for scoring or dull areas. If there is any evidence of this, unless it is very minor, then you should renew the damaged part. The pistons are much more likely to suffer most.

If the unit is sound, soak it with clean brake fluid and then use a new piston seal set for both caliper halves. Never reuse old seals. Keep everything very clean and well soaked in fluid, including the new seals. Reassembly is a reverse process of disassembly. Check the piston's action before installing the caliper back on the machine. Refit the brake pipe and bleed the brakes.

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