mucking around with calipers today.

Originally Posted by husky03

never gave that a thought pete-all comes down to costs though-if the two allen key bolts need replaced its £7 for 2,few quid for new pins if needed, then seals etc, before you know it your £25 quid in parts alone -the O ring is a pain in the ass to get -you need to go for a different bike caliper seal kit that includes it but its the same kit as the sv.
i'm gonna be getting a mini oven to bake the paint dry in future.
I'm gonna do a set of front and rear calipers in dark gunmetal grey to match the wheels in the future once the bikes mot'd.

Update re putting back together will be done tonight.

Yeah, I know the cost keeps mounting up. There was a rumour that some GSXR calipers use Ti pistons that fit the rear. Don't know if that would make them any less prone to binding though. Anyway good to see someone helping to keep the curvy alive

Originally Posted by petevtwin650

Yeah, I know the cost keeps mounting up. There was a rumour that some GSXR calipers use Ti pistons that fit the rear. Don't know if that would make them any less prone to binding though. Anyway good to see someone helping to keep the curvy alive

yeh your right re the gsxr thing pete-a few calipers i've done have got the pistons from the gsxr fitted-there better due to the raised edge at the pad side but as normal there more expensive -the seal kit thats going on the caliper getting done today is £26 from robinsons, i'm gonna change the soft allen key bolts to something else as there just too much bother getting off-where did you get the bolts from that you changed on your curvy choke plungers?

H, they were stainless cap head/allen bolts that came with the carb jetting kit. I'd have thought stainless allen or hex head bolts, suitably copperslipped, would do. The seal kit should really come with new bolts, as it's nigh on impossible to get those stupid OEM ones out without destroying them. You have the patience of a saint!

[dyzio]

Originally Posted by petevtwin650

The ridiculous thing is that folks think Brembo stuff's expensive, but a brand new rear caliper, with pads, is under 50 quid!

7th down on this list: http://www.jaysperformance.co.uk/brembo.html

Maybe I should just buy new callipers instead of trying to dismantle/clean the old ones

Originally Posted by dyzio

Maybe I should just buy new callipers instead of trying to dismantle/clean the old ones

Certainly the rear isn't worth messing about with if the Goldline one will fit, and I've sent you a PM re the front ones, Dyzio.

[yorkie_chris]

Originally Posted by petevtwin650

Lot of effort there Husky Nice one

Have you considered Hard Anodising? Not that I know a lot about it, but the Duke calipers appear to have that finish, inside and out, and I presume that's why they don't gunk up around the seals.

Have you found a source for the little O ring that goes between the two halves?

If you could hard anodise calipers it would be bloody excellent. It is one thing I keep meaning to try but never get time.

However I hear cast ally is not the ideal substance... and clearing the old finish off the top would be hard work.

[yorkie_chris]

Originally Posted by petevtwin650

The ridiculous thing is that folks think Brembo stuff's expensive, but a brand new rear caliper, with pads, is under 50 quid!

7th down on this list: http://www.jaysperformance.co.uk/brembo.html

Someone needs to design a mod that could use it instead. I think YC has got one on his Curvy.

Sorry for the derail Husky

It is honestly not a hard mod to do... you save a load of unsprung weight and get a nice neat place for a speedo sensor if you GSXR-ify the front.

Originally Posted by yorkie_chris

It is honestly not a hard mod to do... you save a load of unsprung weight and get a nice neat place for a speedo sensor if you GSXR-ify the front.

i have to say if i could get one to fit i would, shame you need a new mount (or is that only curvy ?)

[yorkie_chris]

You can get one to fit, talk to twf.

You do need new mount but it is easy

Well time for the rebuild-

second coat dried, so put it back together-

start off with this-


small smear of rubber grease in recess prior to fitting seals


then fit the seals


piston time- again a smear of rubber grease


then gently push into the caliper


two halves back together with plenty of copper grease on the caliper bolts(i always fit them in the back of the caliper first to get the threads a good coating of grease)
same with the bleed nipples, then fit it all together.


from the above pic you'll see that the other half of the caliper has had the brake pad pin holes drilled through, much easier for future brake pad changes.

pins and holes get good dose of copper grease and then fitted, retaining pins fitted,bleed nipple covers fitted then whole caliper gets a wipe with a copper grease rag(found that it tends to stop the caliper getting grotty with road carp)



add pads,fit dust cover, fit to bike and bleed, then ride like a loon and hit the anchors-you know that the back one will work for a while atleast

hope this maybe help anyone who doubts they can service there own calipers.
H.