Re: Caliper overhaul.
 

If i'm just taking the pads out and cleaning around the cylinders, I don't need to detatch the brake hose?

I've got braided lines, how would I go about clamping them if I want to entirely remove the caliper so I can clean it inside? What do I need to think about if I do it this way?

Re: Caliper overhaul.
 

i put alot of grease on the lever and spring the other day and still wouldn't return all the way back every time, would simply taking the master cylinder apart cleaning it all and re-assembling be of use you think??

i will be re building the callipers as soon as i get the seals and rubber grease through, just wondered about the master cylinders as whilst ive drained the fluid i may as well check they are ok too

cheers

Re: Caliper overhaul.
 

No, assuming by cylinders you mean the pistons.

Have you checked the fluid level first?

Have you cleaned the rear pistons?

Have you tried to bleed the system?

I would do all the above first before considering anything else, it could just be a simple solution.

Re: Caliper overhaul.
 

Are you going to remove the pistons? If not you can keep them attached to clean the inside of the calliper, just don't press the lever as the pistons will move outwards and you will have to push them back in again.

Re: Caliper overhaul.
 

fluid level if between min and max, im going to clean the pistons soonish same time as the fronts and ill wait untill then to bleed the system! ill let you know what happens

cheers

Re: Caliper overhaul.
 

Sorry yeah I just meant the pistons.

I think I might just leave the pistons in this time and then remove them in the spring when I do a full strip and clean of the bike. I've seen tools for removing the pistons and for bleeding the hoses, are these required for a full service?

Re: Caliper overhaul.
 

When you do apply some Red Rubber Grease to the pistons...

http://forums.sv650.org/picture.php?...pictureid=1342

I personally use a pair of Sealey VS1806 (pictured above) to remove the stubborn pistons, as for bleeding all you need is a 8mm spanner and a piece of tube.

Re: Caliper overhaul.
 

And some brake fluid!! :smt100

Re: Caliper overhaul.
 

quick question. Stainless pinr replacements don't require a certain grade of stainless? But i take it the better the grade the stronger it is?

Re: Caliper overhaul.
 

Loads of different grades of stainless, some are free machining, some are total bitches, some tough, some brittle etc. Don't worry about strength as pad pin isn't particularly stressed. The stuff used for marine external fittings might be good for it.

Re: Caliper overhaul.
 

was gonna knurl the end to aid getting it in and out of the caliper when neccesarry. Only problem is gonna be cutting a thread for the rear one altho it might not get changed.

Re: Caliper overhaul.
 

Any high temperature silicon grease works fine. It must be high temperature as the brakes get really hot sometimes and you can't have the grease melting away. I also smear a load of the stuff on the outside of the caliper for added protection from salty water without getting any on the brake pads of course.

Re: Caliper overhaul.
 

Silicon grease I don't see why not. Only possible problem is if it has some kind of reaction with brake fluid

Re: Caliper overhaul.
 

No reaction, been using it for years with good results. I got the advice from a good mechanic friend of mine way back when I used to soup up Ford Escorts :) Once I got overboard with it and got quite a bit into a master cyclinder. The grease just surfaced to the top which I removed with a bit of tissue paper. Everything still worked out great.

Re: Caliper overhaul.
 

ok so urgent advice needed right now :( in trying to remove the pad retaining pins (they were very seized so had to take a hammer to them) are now bent and stuck half way out, when i say bent it is minimal and also for all i try i cant pull them out no matter how much penetrating spray i use....HELP please!!!

cheers

Re: Caliper overhaul.
 

WHen you say half way out how far out are they?
You coulld try cutting the pins and then knocking the smaller pieces out or you could try a bit of heat on them

Re: Caliper overhaul.
 

about 1cm out so not quite half way...

Re: Caliper overhaul.
 

Are they clear of the blind hole they go into?

Re: Caliper overhaul.
 

if we are thinking the same thing then yes they have come out of the hole by around 1 cm

Re: Caliper overhaul.
 

If I was you then I would just cut the pins and bin them seeing as they're bent now anyway

Re: Caliper overhaul.
 

yeah ive got new ones anyway so ill go try and cut them, also as its the rear calliper when trying to undo the caliper joining bolts they have rounded :( going well isnt it!!!

Re: Caliper overhaul.
 

Ah bugger that definitely makes it a bit harder, if they hadn't have rounded you could've split the caliper to get the pins out

Re: Caliper overhaul.
 

Now would be a good time to get some replacement bolts, preferably stainless hex head. Any bolt which is torqued quite high or in a vulnerable state shouldn't really be allen head in my opinion.

How badly are they rounded?

+ 1, and remember to copper grease the new ones.

Re: Caliper overhaul.
 

dangerous dave, have you got any part numbers for stainless bolts?? they arnt too badly rounded but for the life of me i cant move them any ideas??

got one of the pins out now btw which is good now just for the other one!!

Re: Caliper overhaul.
 

ok ive got both pins out but have no way of getting those joining bolts out, what do i do as i cant see both pistons coming out with it joined and the heads now look like stars but even using a star socket it wont budge... anyone?

Re: Caliper overhaul.
 

File a flat head and try an impact driver and big hammer, or drill them.

Re: Caliper overhaul.
 

I 2nd that sentiment although I didn't quite get around to replacing the bolts on mine.

On a previous rear caliper rebuild i managed to snap my Halfords pro allen socket on the bolt :takeabow:

Re: Caliper overhaul.
 

I have a feeling they're fine pitch, not sure though.

Re: Caliper overhaul.
 

exactly what ive done!!!


what do you mean by this??

Re: Caliper overhaul.
 

also how do you go about drilling them?? surely that would mean i have to re thread them?

Re: Caliper overhaul.
 

Usual bolt is known as "metric coarse" pitch... like M8 x 1.25 ... metric fine would be (iirc) M8 x 1.00, the threads closer together. A few places on the SV use fine pitch ... such as the bolts holding subframe on. Calipers might, like I say I'm not sure.

And nah, I mean drill the head off, so you can split the caliper and get to the shaft of the bolt with serious heat and a vice.

Re: Caliper overhaul.
 

ohhh so there isnt actually any thread on one side of the calliper?? ok ill go do that then cheers :)

Re: Caliper overhaul.
 

No, only the wheel-side is threaded. That's how most fixing bolts work ;-)

Re: Caliper overhaul.
 

ok well i dont have a big enough drill bit so that will have to wait untill the morning does anyone know the right size for replacement bolts???

many thanks :)

Re: Caliper overhaul.
 

anyone???

Re: Caliper overhaul.
 

im going to cry!!!! started the front callipers and one of the pistons came out very happily but the other is giving my hastle and is stuck, now all the fluid has gone and i have to buy another tool to get this done :(

Re: Caliper overhaul.
 

are these the only things for the job??

Re: Caliper overhaul.
 

That's what i used before on a few calipers until me and thedonal managed to break it doing his front calipers

Re: Caliper overhaul.
 

No you don't. Refit the piston that came out and hold it in position with a G clamp or similar. Top up with fluid and pump out the stuck piston that way.

Or use compressed air if you have a source.

Re: Caliper overhaul.
 

Yarp. Suzuki have politely provided you with a very high powered hydraulic piston removing tool ;-)