Caliper plug tool

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Coolhands

Coolhands

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Do I need to but the tool to get that plug out? What creative options work for you?
 
It's called a peg spanner. Something very similar is used to tighten the spindle nut on an angle grinder, and Home Depot etc. has universal adjustable versions of those. Or, you could fabricate one.
 
Coolhands said:
Do I need to but the tool to get that plug out? What creative options work for you?
Click to expand...
Heat and tool 06.3965 (06.1007). AN is out of stock right now, but others in the states have them. It has multiple functions including that cover and wheel bearing retainers.
 
Heat the caliper to release the plug. I had these on hand already:
Williams 483 Adjustable Face Spanner, 3-Inch
 
in my case, i had to revert to buying the tool. my Mk2 sat for years, and the caliper plug was pretty much frozen to the caliper. i probably had a bit of galvanic corrosion, and when i finally got the thing open, the rusty sludge inside looked like it came from the wreck site of the titanic. it took the spanner, along with a socket, and an impact wrench to break things down. i have in the past made a similar tool from an old socket - find the appropriate OD socket and notch out the sides. if the plug is not too stubborn, it should come out without much difficulty. as i recall, i'm thinking the plug is only torqued to 26 ft.lbs.
Caliper plug tool
 
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Two dowel pins (.250 ?) and a bar. I made a plate I can bolt the caliper to so I can clamp it in the vise.
 
I addressed this some time ago. See the first part of my first post here:
jaydee
www.accessnorton.com

Newbie Restoring 75 MK3, First Post:

I've been reading a lot on here as I work on my bike, thought I'd sign in and participate. I bought a new Norton in 75 and sadly must admit I haven't ridden it in over 20 years. I had it covered up with a sheet in the basement. I recently drug it out and began to inspect. The most apparent...
www.accessnorton.com www.accessnorton.com
 
Coolhands said:
Do I need to but the tool to get that plug out? What creative options work for you?
Click to expand...
Caliper plug tool


After applying heat, the plug can be loosened with the caliper attached to the fork slider.


To remove the outer piston, press it inward until the seal is uncovered, then hook out the seal and the piston should slide out as this method is easier than attempting to lever the piston out from the disc slot.

When refitting the inner piston I recommend that it is only pressed in just far enough for the brake pad to be fitted. If the inner piston is pressed all the way in, then it can blank off the drilling, making the inner piston/bore extremely difficult to bleed.
 
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