Author Topic: Brake Caliper Balls-Up (Read 19795 times)

greywolf · « **Reply #20 on:** February 09, 2014, 13:44:11 »

The pistons are the same size. The calipers for ABS and non ABS have different part numbers.

Juvecu · « **Reply #21 on:** February 09, 2014, 13:45:13 »

Yes, that was just me getting confused with the OEM callipers and the CBR600 callipers I have on my bike as an upgrade

Descolada · « **Reply #22 on:** February 09, 2014, 15:01:55 »

So I went out with my trusty vernier caliper earlier and got readings that don't seem to tie up with what I have seen online (http://www.wemoto.com/parts/) .

The outside diameter of the pistons (both of them) is 26.9mm and the length (depth) seems to be 25.57mm - does that tie up with anything for piston sizing?

At the moment I am angling towards this kit but it specifies DL1000 and I haven't got a response to my enquiry as yet. http://www.ebay.co.uk/itm/Suzuki-DL650-DL1000-DL-650-1000-V-STROM-Tokico-brake-caliper-seal-repair-kit-/150970480378?pt=UK_Motorcycle_Parts_13&hash=item23268ab6fa

Juvecu · « **Reply #23 on:** February 09, 2014, 15:14:09 »

Seal measurements are going to be OD. Measure the old seal thickness, double it and add that to your piston OD.

That kit you linked looks like the right stuff. A multitude of bikes use the same callipers as the DL650 and DL1000. Lots of the Jap manufacturers use these on various bikes.

Descolada · « **Reply #24 on:** February 09, 2014, 15:24:35 »

Thanks Juv, I finally made my mind up and pimped for two of the Powerhouse kits. If I can get the extra caliper set I will keep those as a standyby for quick switching.

Jacko · « **Reply #25 on:** February 09, 2014, 16:23:39 »

Quote from: "Juvecu"

Seal measurements are going to be OD. Measure the old seal thickness, double it and add that to your piston OD.

Don't forget the seals sit in a groove in the piston.

Descolada · « **Reply #26 on:** February 10, 2014, 11:15:37 »

I really hate ambiguity, it tends to lead to mistakes.

So I was looking again at the video "Motorcycle Front Brake Caliper Rebuild" from "Delboy's Garage" on Youtube (you can find it here;

.

He is absolutely clear that nothing other than brake fluid should be used in the caliper piston sockets where the seals go.

But the advice from the folks on this forum is to use red grease on the seals and in the seal seats.

Is this just a case or "There's more than one way to do it"?

Jacko · « **Reply #27 on:** February 10, 2014, 12:08:02 »

Red rubber grease is fine to use, I believe it's even derived from brake fluid, it's perfectly safe to use on the rubber seals, after all that's what it's designed to do.

Descolada · « **Reply #28 on:** February 10, 2014, 13:43:33 »

Yep, that made perfect sense to me, cause it's called "Red Rubber Grease for Use in Caliper Seals" - but all it takes the first time you are attempting something new is a small shred of uncertainty and it all goes out the window. Thanks for confirming this, much appreciated.

Babel · « **Reply #29 on:** February 10, 2014, 17:19:21 »

I'm probably too late to this thread, but the caliper seal sets are less than half the normal RRP during Suzuki's Bike Of The Month promotion this month (just got some myself): https://www.Suzuki-gb.co.uk/motorcycles ... the-month/

Descolada · « **Reply #30 on:** February 11, 2014, 10:08:11 »

I have to say I am really not enjoying this maintenance. I finally worked the pistons out of the caliper last night and they look rough, too rough to polish up and put back. Whether it was me, or some previous owner that did the damage is irrelevant at this point, I need to replace them.

The reason the caliper carrier would not come off is because the hole the long rubber boot goes into is encrusted with salt build-up and all kinds of muck. It was basically pinching the pin so hard it could not move and I need to get in there to remove all that mess. For now my only option seems to be a medium needle file but I am very nervous about damaging the hole using this method.

With regards to the pistons, I have to admit I got a little confused as the thread expanded to include different sized pistons etc, especially the difference between earlier calipers and those on my ABS K9.

So unless anyone else has a better (cheaper) supplier they can let me know about I am going to contact Suzuki using the link provided by Babel yesterday and get them from there. But that price seems to include a single piston and I haven't even looked at the off-side caliper yet.

This is turning out to be an expensive job

frez · « **Reply #31 on:** February 11, 2014, 10:19:39 »

The DL650 is Suzukis Bike of the Month, you may find the parts are much cheaper ordering them online this month. Don't get them from the dealer as they don't give you the Bike of the Month discount, you have to order them online, you can then get the parts delivered to the dealer or sent to your home.

Descolada · « **Reply #32 on:** February 11, 2014, 10:33:20 »

Thanks Frez, I have that page and have confirmed the following;

Part Number is 59300-01820 - Confirmed earlier in this thread - same as a Suzuki SV650 K5

Wemoto's best price this morning is £26.28 FOR EACH PISTON & SEAL

The "Suzuki Bike of the Month" deal is matched to 59300-01820 and is £19.31 FOR EACH PISTON & SEAL

At this point I am going to call Suzuki and double check that they have stock.

Anyone do better than this please ?

Jacko · « **Reply #33 on:** February 11, 2014, 10:43:52 »

Can't you get hold of a pair of recon callipers off a breaker on eBay?

Also, use small lengths of wood to break up all the salty gunk in the holes, it won't damage the alloy.

I know it all seems like grief at the moment, and I'm sure it is, but when it's done you'll be wiser and more experienced, ready to pass it on later.

Descolada · « **Reply #34 on:** February 11, 2014, 11:12:05 »

Jacko, yes that's good advice. I understand that it will be a good learning process and I am, in fact, benefiting from it, but I hate screwing around with brakes. It's just one of those times when you think you are going to a a nice quick turn around in a standard maintenance task and it snowballs into something you feel you have barely any control over.

I need to control my sense of panic.

OK, so I have done the dirty with Suzuki and ordered two of their piston and seal kits. The whole thing came to £38.62 and I thought "Yippee", until I say the postage. £5 for a measly 3-7 day turn around - BAH!

By now I resemble one of these (the purple ones)

[youtube]http://youtu.be/u6RxZK3LTnA[/youtube]

Worryingly when I entered my VIN number it went red and told me my bike was not eligible! (again with the purple minion) - BAH!

On a hunch I decided to proceed anyway, the worst that could happen was a couple of people from Suzuki would turn up at the door and demand the parts back. The purchase went through smoothly and no one was any the wiser.

So now I have a week off the road to clean the caliper and get it all ready to go back together (I should probably check the off-side caliper and get it over and done with. Incidentally, I struggled like buggery to get that stuck piston out of the caliper. The dust seal had bulged out almost all the way round and it was stick fast. In the end I carefully prized it loose and then pulled it out in one piece. TAH DAH! (thinking of minions here again).

The seal recessed on the caliper are caked with salt and that was probably what pushed the seal out in the first place. I need to be very careful cleaning all that crap out not to damage the recess for when the seals go back in.

BAH! :angry-cussingblack:

KLV-Rider · « **Reply #35 on:** February 11, 2014, 11:13:16 »

Quote from: "Jacko"

I know it all seems like grief at the moment, and I'm sure it is, but when it's done you'll be wiser and more experienced, ready to pass it on later.

+1

Descolada · « **Reply #36 on:** February 11, 2014, 11:23:52 »

By the way chaps, if anyone sees a set of calipers for a 2009 ABS wee on ebay (or at a breakers) please give me a shout?

wal750 · « **Reply #37 on:** February 11, 2014, 12:02:06 »

Those calipers really don't look that bad. The sliding pins will clean up with some emery and the pistons can be cleaned with some very fine wet and dry if they require it. Usually the pistons are only corroded on the exposed areas which isn't normally a major problem. The caliper oil seals generally never need replacing in my experience, it's always the dust seals that give the problem.

Before fitting the new dust seals it is imperative to meticulously clean the recess using a small screwdriver or a scribe, the aluminium corrodes behind the seal which pushes it against the piston causing the stiction. Once you've scraped the corrosion away it then needs a thorough clean, I tend to use brake cleaner or whatever solvent cleaner I have on the shelf along with an old toothbrush.

You can use the red rubber grease but I always lubricate the pistons with fresh brake fluid to push them back. Crack the bleed nipple beforehand to allow them to go back more easily, if you have to use excessive force it's because the piston isn't square in the bore or the dust seal is catching.

Good luck with the rebuild.

bosnjo · « **Reply #38 on:** February 11, 2014, 13:07:25 »

I really don't know if this apply for your stuck carrier...
When I was learning car mechanics in one old bloke's garage, 30 years ago, there were many cars coming in with parts that needed to be disassembled, as at that time parts were usualy rebuilt and rarely replaced. I remember from that period, whenever we had a part that was full of gunk, salt and everything else, completely stuck and therefore impossible to disassemble, we would let it submersed in the diesel fuel during a night. And I mean really submersed. In 95% of ocasions, in the morning the part was completely loose and easy to work on as if it was new.
That was back then and that is what I'd do today whenever I have this kind of problem.

Descolada · « **Reply #39 on:** February 20, 2014, 15:44:59 »

Geez, this has dragged on and on. Eventually had to get two sets (of pistons) and got the dispatch note from Suzuki - 7-10 days till delivery - WTF. Tracking information was all screwy so I tracked the 'authorised reseller' to Redcar Motorcycles. Gave them a call today and got a story about them being in stock when I ordered them, but then they weren't - Suzuki screwed up. So one set has arrived and 'will be with you on Saturday', the other will arrive next week.

The bloke was very polite and apologised profusely - so I couldn't fault them on that front. Turns out they just won "Dealer of the Year" from Suzuki.

In the meantime there has actually been Sun in the sky. You should know once this job has been done and I'm back on the road - cause the heavens will open for the next two weeks (sorry in advance).