:dunno we'll see :lol
Yeah, it's a straightforward process.....I wrote this up on the WERA forum, I think it pretty much details everything you need to do. If you have any questions just ask.Cool, is it pretty straight forward? I do have the manual, and am about to replace all brakes and bleed the Joe way. So is it ok to soak the seals in soapy water?
It definitely doesn't hurt to split the calipers and give everything a good cleaning, especialy if any dirt or crap worked it's way past the dust seals and are wedged between the dust/oil seals and piston.
It was kind of detailed already, but the easiest way I've found to get stubborn (or really any pistons) out of the caliper is like this, the idea is to avoid the compressed air/piston missle approach.
1 - unbolt the calipers and remove the pads.
2 - lay an adjustable wrench in the center channel of each caliper where the rotor is normally sitting
3 - start pumping the lever until all the pistons push themselves out up against the wrench, the wrench is there to keep the faster moving pistons in place until the rest come out.
4 - pull out the wrenches and start pumping again, over a bucket or something until the first 1 or 2 start popping out (and fluid too obviously).
5 - unbolt the calipers from the hoses and split the calipers with the correct size Torx bit, I think the GSXR's use a T-40
6 - by now the pistons should be out far enough to wiggle out with your fingers or if need be cover the end with a rag and carefully wiggle them out with a needle nose plier
7 - now you take all the seals out carefully with a small flat bladed screwdriver. It is recommended to replace all the seals when rebuilding the calipers, but I've reused them on several calipers and had no issues. Just take them out very carefully so you don't gouge them, and wash them with hot soapy water and dry them off (NO brake cleaner or solvents).
8 - give the caliper bores and passages a good cleaning with brake cleaner if you like (assuming you have all the rubber seals out now). and blow everything out with compressed air so it's spotless. If you can't get the pistons completely clean of the caked on crud I've found that Scotchbrite cleans that shit off good without scratching the surface.
9 - finally coat all the seals and pistons in fresh brake fluid as you are putting them back in and reassemble.
I just did this whole process on a set of 04 GSXR-600 calipers that would barely move. After this they were working perfectly again.
Just got done rebuilding/cleaning my front calipers... I like to make sure everything is right because my wheel was free spinning for way too long. I initially was just going to take the front rotors off, and de-glaze them.
When I had my left side caliper off with the right side one still on, I hit the brake lever a couple times just to see what the scoop was. The inside pistons of that caliper didn't move at all. So, I took them apart and broke them down.
A really easy way to get the pistons out is to blow about 30psi of compressed air into each housing. They pop right out. I cleaned the pistons real good (scotch brite), and the seals with soapy water. When I went to assemble them I made sure everything was spotless. I lubed everything up with some brake fluid, and pushed them in and out using compressed air to make sure everything was functioning that I could see.
Oh yeah, the right side caliper had some milky looking shit in both of the housings when I cracked them open. I've never seen that before. It didn't smell too good either. I had just flushed the entire brake system front and rear before my first track day a couple weeks ago.
I did note that going out on one session before I entered the track I went to hit my front brakes, and the lever came all the way back to my knuckles. Hmmmm.... Don't know what caused that, but I just adjusted the lever out to where it didn't hit and rode with it.
Now, I'm waiting on an adapter for my power bleeder. I have a might vac too, but its just so damn quick to flush an entire system with one of these units. Should be here wed, so I'll make good use of down time. I'll probably tackle servicing the forks while everything is off.
O, and its a T30 torx bit for breaking the calipers in half. It's a fairly easy task. Just take your time.
I did hesitste at first also. I tried a toothbrush first and it was a no go. I did this with the piston out of the caliper. the only other thing I had handy was a brass wire brush that felt soft on my hand where I tried it first. I gave it a try and i had no problems. I would say should not be the first option but it worked for me. But I will be getting some scothbrite for the next pair I do.I hesitate to use anything that stiff. Risk of seal damage. A tooth brush seems to work fine for me