Any and all advice appreciated.
getting pistons out of old calipers
I bought some very used Tokiko 6-pisotn calipers on-list, supposedly from a TLR, to install on my TLS. The pistons appear to be coated with some gold-colored coating which I don't recall seeing on my older TLR calipers. I sprayed on lots of brake cleaner, and cleaned them up with a parts brush, Q-tips, and paper towels. I made a bar that goes down the middle (in place of the shoes & pads) to stop pistons on one side from popping all the way out. I used a rubber-cone fitting on an air gun to attempt blowing all the pistons most of the way out. But on one caliper 2 pistons didn't move, and on the other caliper 3 didn't move.
I imagine I need much more air pressure. Or I could hook the hydraulics back up. If I use pliers or something like that I'll need to replace the pistons for sure. I hope the calipers are OK and haven't been dropped, bores still round...
I figure if the pistons don't move easily with air & my fingers these things are badly in need of a thorough rebuild.
I imagine I need much more air pressure. Or I could hook the hydraulics back up. If I use pliers or something like that I'll need to replace the pistons for sure. I hope the calipers are OK and haven't been dropped, bores still round...
I figure if the pistons don't move easily with air & my fingers these things are badly in need of a thorough rebuild.
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OK have we had this discussion before? According to the fiche at RonAyers.com the pistons and seals have been discontinued!!! How can that be possible?
What's another fiche site? This is bullshit.
What's another fiche site? This is bullshit.
...and the Hayabusa 6-piston tokico calipers do have pistons sets and seal sets available. WTF?
i use a grease gun
the nozzle on mine unscrews and the thread sort of screws into the caliper.
just enough to work without damaging anything.
I place a piece of 1/4 plate in the gap and pump the pistons out with grease
once they are all resting on the plate I disassemble the calipers and the pistons come easily and clean it all up
the nozzle on mine unscrews and the thread sort of screws into the caliper.
just enough to work without damaging anything.
I place a piece of 1/4 plate in the gap and pump the pistons out with grease
once they are all resting on the plate I disassemble the calipers and the pistons come easily and clean it all up
pistons clean up with 800 W&Dry
seal are reusable in most cases
dust seals can be a problem tho so handle them carefully
seal are reusable in most cases
dust seals can be a problem tho so handle them carefully
If I get it apart I'll put in new pistons & seals. First I probably should find somebody with 150 PSI of air pressure. And now that I made a piston-retention plate to replace the pads & discs I'll always make sure I pop the pistons that far before removal from the hydraulics.
Last time I stripped a troublesome caliper, I hooked up the master cylinder directly to the caliper, bled it, then pumped out the piston with that. Worked a treat, if a little time consuming to set up. I have a small block of wood about 15mm thick that I put between the pistons, then I can just pump out until all six pistons are in contact with it. If you're going to split the caliper halves I'd suggest loosening the four joining bolts slightly whilst the calipers are still in situ on the bike. The fork legs make a pretty useful caliper counter-holding tool 
I used one of these seal kits for the last few years:
http://www.ebay.co.uk/itm/Suzuki-GS...pt=UK_Motorcycle_Parts_13&hash=item2325d107ee
And had no trouble with them. My preferred Suzuki dealer also now stocks the same brand of pattern seals.
Parts Diagrams -> Suzuki Motorcycles
I used one of these seal kits for the last few years:
http://www.ebay.co.uk/itm/Suzuki-GS...pt=UK_Motorcycle_Parts_13&hash=item2325d107ee
And had no trouble with them. My preferred Suzuki dealer also now stocks the same brand of pattern seals.
www.alpha-sports.comOK have we had this discussion before? According to the fiche at RonAyers.com the pistons and seals have been discontinued!!! How can that be possible?
What's another fiche site? This is bullshit.
Parts Diagrams -> Suzuki Motorcycles
In later years Tokico put some sort of clear coating on the pistons. It feels like teflon. If yours have that, I'd stay away from sanding them. If they're discontinued and you need some, I'd consider getting your old pistons coated with DLC (not cheap).
I make a spacer out of wood paint stirring sticks. It has to be thick enough to prevent the pistons from popping out, as once one pops you won't have any pressure for the others. 100 psi should be plenty. If some are badly stuck, I'd start with the pads installed. Then switch to something thinner once they've all moved. After they're extended as far as possible, take the caliper apart and you can wiggle the pistons the rest of the way out.
There are tools for this, Sealey VS1806 and Draper 30838. But they're hard to find in the US.
I make a spacer out of wood paint stirring sticks. It has to be thick enough to prevent the pistons from popping out, as once one pops you won't have any pressure for the others. 100 psi should be plenty. If some are badly stuck, I'd start with the pads installed. Then switch to something thinner once they've all moved. After they're extended as far as possible, take the caliper apart and you can wiggle the pistons the rest of the way out.
There are tools for this, Sealey VS1806 and Draper 30838. But they're hard to find in the US.
Camper, I have a spare set of good calipers from my R. Do you want 'em?
I went to a friend's house and got 120 PSI. A quick spray of break cleaner, then I pushed the pistons in to break them free. Got all of them popped out most of the way.
Yes, the later Tikoco calipers for the Hayabusa had some kind of coating. I think some even had titanium pistons??? I'm almost certain I ran into this same problem before (ronayres showing disocnuntinued) but was able to buy pistons & seals for my TLR from the dealer. So I don't think these parts are really discontinued, but are perhaps superceded by the coated ones. Bike shops here are closed on Mondays, I'll have to stop in again tomorrow.
Meanwhile I'll check alpha-sports unless they're overseas.
Yes, the later Tikoco calipers for the Hayabusa had some kind of coating. I think some even had titanium pistons??? I'm almost certain I ran into this same problem before (ronayres showing disocnuntinued) but was able to buy pistons & seals for my TLR from the dealer. So I don't think these parts are really discontinued, but are perhaps superceded by the coated ones. Bike shops here are closed on Mondays, I'll have to stop in again tomorrow.
Meanwhile I'll check alpha-sports unless they're overseas.
Well, these were supposed to be good calipers from a TLR...but they were pretty well-used. Let me see how this goes; they should be good with new seals & pistons.Camper, I have a spare set of good calipers from my R. Do you want 'em?
TLR junkie, yes I made a nice tool out of aluminum so no individual piston can pop out far enough to leak.
Gads, the seal kit is $103.46 from the UK to USA
Gads, the seal kit is $103.46 from the UK to USA
OK the early Hayabusa calipers also show "discontinued" but the K3 Hayabusa shows:
59301-33861 PISTON SET $86.19
59300-33881 SEAL SET, PISTON 41.03
127.22
X 2
= 254.44
Man that's a lot. Unless the piston set includes the seal set???
Then I'd add speed bleeders while I'm at it.
59301-33861 PISTON SET $86.19
59300-33881 SEAL SET, PISTON 41.03
127.22
X 2
= 254.44
Man that's a lot. Unless the piston set includes the seal set???
Then I'd add speed bleeders while I'm at it.
They are the set in the pic below. Yours free with an extra rear caliper if you change your mind. I may even have a spare set of R braided lines.Well, these were supposed to be good calipers from a TLR...but they were pretty well-used. Let me see how this goes; they should be good with new seals & pistons.
Damn that's generous.
If you feel like coming over and helping me pull wrenches, I could use that too.
If you feel like coming over and helping me pull wrenches, I could use that too.
I'd rather see the spares go to a long-standing member of the community than sit around collecting dust in the garage. Particularly if I don't have the hassle of packing and shipping, since you live a short distance away.Damn that's generous.
If you feel like coming over and helping me pull wrenches, I could use that too.
I rarely turn wrenches anymore. My time is better spent with my family.
Every Suzuki I've bought parts for, you can either buy:...
Man that's a lot. Unless the piston set includes the seal set???
...
a) Just seals (caliper halves, fluid, dust)
b) Pistons and seals
AFAIK you can't buy pistons on their own. I guess the logic is that you wouldn't be re-assembling calipers with old seals, and they have to come apart to replace pistons.
I would say with 99% certainty that price for the pistons would include the seals.
Thuddds better known as Supracharged... I have to admit I need them, and will gratefully take them. Do you have any master to sell too? I wanted to get the red Beringer to match the thumb brake master for the rear brake on the other side, but I have to have this running and on the trailer really soon, and I'm running out of money fast.
Yes, "Suprachrgd82" until the Zone crashed a few years back and I had make a new username.Thuddds better known as Supracharged... I have to admit I need them, and will gratefully take them. Do you have any master to sell too? I wanted to get the red Beringer to match the thumb brake master for the rear brake on the other side, but I have to have this running and on the trailer really soon, and I'm running out of money fast.
I don't have a master. Maybe some other R body parts laying around; front fender, belly pan, chain cover. I'll PM you my # and you can swing by when you have a chance.
By the way, I do recall you were asking the group about red brake rotors a few weeks ago. Have a look for EBC's Vee rotors. They come in red.
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