I have just carried out a refurb on my 1999 GSXR750 front calipers.
They are the 6 pot Tokico ones and when I took them off the bike to clean them noticed that a couple of seals looked poor and that the pistons were not functioning correctly.
With the parts ordered from WEMOTO (new seal kits*2), I cracked on.
Dropped the pads out of the r/s caliper, hung a piece of rubber between the pistons on the right hand side caliper and pumped the lever, this caused all but 1 of the pistons to free off. Pushed the pistons back on the l/s caliper, dropped the pads out, topped up the fluid and repeated the process. 2 stuck pistons in this caliper.
Took thr calipers into work and attached an air line to them and with assistance the stuck pistons came free
Split the calipers and the dust seals were in a very sorry state, the oil seals were not too bad, but were all being replaced anyway. The amount of crud behind the dust seals took some shifting, but with trusty brake cleaner came away sparkling in no time.
The new seals were fitted and the calipers re-assembled, new o rings between the caliper halves. I then proceeded to fit my new braided lines (HEL). The tricky part of bleeding the system then took place. The master cylinder was tapped to attempt to remove as much air as possible and the brake lever tied back overnight.
The braking results are much better than prior to the new seals, although I think a new master cylinder may be required as it is weeping slightly.
It's not an overly difficult job and doing it myself certainly saved a fair amount of cash. Anyone with minor mechanical skills should be able to carry out the repairs.
They are the 6 pot Tokico ones and when I took them off the bike to clean them noticed that a couple of seals looked poor and that the pistons were not functioning correctly.
With the parts ordered from WEMOTO (new seal kits*2), I cracked on.
Dropped the pads out of the r/s caliper, hung a piece of rubber between the pistons on the right hand side caliper and pumped the lever, this caused all but 1 of the pistons to free off. Pushed the pistons back on the l/s caliper, dropped the pads out, topped up the fluid and repeated the process. 2 stuck pistons in this caliper.
Took thr calipers into work and attached an air line to them and with assistance the stuck pistons came free
Split the calipers and the dust seals were in a very sorry state, the oil seals were not too bad, but were all being replaced anyway. The amount of crud behind the dust seals took some shifting, but with trusty brake cleaner came away sparkling in no time.
The new seals were fitted and the calipers re-assembled, new o rings between the caliper halves. I then proceeded to fit my new braided lines (HEL). The tricky part of bleeding the system then took place. The master cylinder was tapped to attempt to remove as much air as possible and the brake lever tied back overnight.
The braking results are much better than prior to the new seals, although I think a new master cylinder may be required as it is weeping slightly.
It's not an overly difficult job and doing it myself certainly saved a fair amount of cash. Anyone with minor mechanical skills should be able to carry out the repairs.
in the end had to blow torch the outer seals 