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L3on
Site Manager
Joined: 08 Jun 2007
Posts: 2884
Location: Berkshire
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 Posted: Fri Mar 28, 2008 6:50 pm Post subject: Caliper Strip & Rebuild in Pics |
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Replaced the seals in my calipers today, as 1 piston was sticking, so took some pics & decided to do it as a 'how-to' thing.
from my 750K0, but common to many models, removal may differ, but the calipers are pretty much the same.
Remove 5mm allen bolt (A) retaining pads after removing r-clip from behind and ever so slightly loosen 14mm Banjo bolt (B) to make removing later easier, then remove 2 mounting 12mm bolts (C)
Remove anti-rattle plate by removing 3mm allen bolts (D)
Pump brake lever until a couple of pistons are NEARLY out
Remove the pistons that moved whilst pressing brake lever, remove their seals and clean up the pistons, then put the pistons back into the caliper without the seals after cleaning
using a clamp & some pieces of wood & an airline, clamp the 2 pistons without seals that you have refitted in the step above & and use the airline to push the 2 remaining pistons out of the caliper
Remove all the pistons & clean with a cloth or wire wool, or wet & dry fine grit paper (wet) as required to remove any rust/debris from them.
Remove the remaining seals, then clean the caliper with a good dose of brake cleaner.
fit new seals (in jam-jar having been soaked overnight in brake fluid) ensure that they go in the right way round (mine had a slight v to the inside edge of the top (thin) seal, but they do vary with model)
as a side note, the genuine suzuki seal kit came with 2 more seals per kit that fit between the 2 halves of the caliper, but I recommend that you don't split the caliper apart unless the caliper itself needs a lot of cleaning up before fitting the new seals - the slightest bit of damage or dirt between the 2 faces can knacker a good caliper.
lubricate the cleaned pistons with brake fluid & re-insert them into the caliper, keeping them as straight as possible to ensure they don't dislodge the seals.
Job done, cleaned & ready to re-fit before doing the other side.
Each side took less than an hour each + another 1/2 hour to bleed the brakes afterwards, including taking the pics, but the pistons weren't in a particularly bad condition.
hope this helps somebody out, or encourages them to do another job themselves.
Just be careful when working with brakes & make sure you have the right tools & are confident in what you are doing, please don't hold me responsible if it doesn't go to plan 
Last edited by L3on on Sun Sep 21, 2008 10:44 am; edited 1 time in total |
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rick-uk
MOTO GP rider
Joined: 20 Aug 2006
Posts: 3545
Location: Ipswich, Suffolk
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| Posted: Fri Mar 28, 2008 7:40 pm Post subject: |
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| Thats brilliant mate! Top job for doing a step by step guide with photo's. Can we make this a Sticky or something?? |
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fletchos
wheelie God
Joined: 12 Jan 2008
Posts: 406
Location: Calne , Wiltshire
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| Posted: Fri Mar 28, 2008 7:47 pm Post subject: |
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cheers fella that was very useful  |
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Fishy
Captain Nemo
Joined: 19 May 2007
Posts: 5384
Location: 20,000 leagues under the sea
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| Posted: Fri Mar 28, 2008 9:01 pm Post subject: |
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It still sounds like someone speaking Swahili to me  |
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dazzygsxr750
trackday god
Joined: 21 Nov 2006
Posts: 1753
Location: wrexham,north wales
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| Posted: Fri Mar 28, 2008 9:12 pm Post subject: |
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| great write uo..must add though,if you dont feel competant doing your brakes,then leave them to someone who does |
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ashman
moderator
Joined: 09 Apr 2006
Posts: 6465
Location: Land Ahoy
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| Posted: Sat Mar 29, 2008 6:00 am Post subject: |
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Cheers for that Leon. Would not try it myself I don't think though unless I was with the likes of yourself showing me  |
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andyk3
Site Founder
Joined: 15 Dec 2005
Posts: 21599
Location: Widower to a Nintendo DS
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| Posted: Sat Mar 29, 2008 7:48 am Post subject: |
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| nice job mate |
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EdCase
trackday god
Joined: 15 May 2006
Posts: 1828
Location: 3rd rock from the sun
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| Posted: Sat Mar 29, 2008 7:54 am Post subject: |
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brilliant step by step guide and good clear pics to L3on. nice one mate  |
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coco
Burnout King
Joined: 04 Feb 2008
Posts: 169
Location: SW Scotland
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| Posted: Tue Apr 08, 2008 6:08 am Post subject: |
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| Spot on .......... more of this type of step by step guide would be a bonus. |
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rev gsxr
stunt monkey
Joined: 03 May 2007
Posts: 1116
Location: northampton
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| Posted: Tue Apr 08, 2008 1:42 pm Post subject: |
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spot on that leon  |
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Behold
Ghost Rider
Joined: 05 Mar 2008
Posts: 646
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| Posted: Tue Apr 08, 2008 5:40 pm Post subject: |
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| Top write up with great photo's |
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J.P
scooter boy
Joined: 06 Jul 2008
Posts: 23
Location: swindon
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| Posted: Mon Aug 11, 2008 8:05 pm Post subject: post |
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| also if u have a grease gun u can take the bleed nipple out of the caliper put in grease nipple and push the piston out this way, remove the rubber clean the grease out and finnish off with wd40. its surprising what u can get up2 on overtime when your supposed 2b doing a service on a JCB |
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GSXR_600_K4
delboy
Joined: 20 Nov 2007
Posts: 320
Location: Newcastle Upon Tyne
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| Posted: Fri Aug 15, 2008 6:07 pm Post subject: |
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| Excellent mate, any chance of getting the pics re-hosted ? |
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L3on
Site Manager
Joined: 08 Jun 2007
Posts: 2884
Location: Berkshire
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| Posted: Sat Aug 16, 2008 2:30 pm Post subject: |
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| not sure whats happened to the host imgpire, worked ok the other day, i'll have to dig out the photo's & find another host site. |
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andyk3
Site Founder
Joined: 15 Dec 2005
Posts: 21599
Location: Widower to a Nintendo DS
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| Posted: Sun Aug 17, 2008 10:45 am Post subject: |
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| L3on use image shack |
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