Rear Caliper

Originally Posted by TSM

if you split the caliper you will need a new gasget

It's not so much a gasket. It's a rubber sealing ring and you shouldn't need to replace it unless it is actually damaged, which I doubt it would be. You just don't need to be ham fisted when splitting the calliper apart.

Take it easy, before you drill anything. First, Have you take out the plastic cover?, Second, the pins can slide out if you take out the two safe wire pins on each slide, Third, carefull with the rare springs holding de pads, push them gently on with a driver and the pins will slide out, if you find some force grab the pin with a plier a spin it out like if it were a screw.
And cover your eyes because the rare spring tend to jump over your face.

Originally Posted by V-Powerplant

Take it easy, before you drill anything. First, Have you take out the plastic cover?, Second, the pins can slide out if you take out the two safe wire pins on each slide, Third, carefull with the rare springs holding de pads, push them gently on with a driver and the pins will slide out, if you find some force grab the pin with a plier a spin it out like if it were a screw.
And cover your eyes because the rare spring tend to jump over your face.

Tried all that on mine - no way the pins were gonna budge. It was either spilt the caliper or drill the bugger, so I drilled the bugger.

[timwilky]

One of my pins came out afer about 2 days soaking in penatrating oil, the second no chance. It sheared off, So had to drill it out. Replacements fitted with loads of copper grease in the blind holes and on the pins and I give them a little twist every couple of weeks. Only takes a minute, but makes sure they are staving free.

If only Suzuki had designed them with a hex head you could get hold of and a through hole. I doubt that it would have cost more than 10 pence to manufacture in the volumes they must use. But think of all the lost sales of replacement pins

On the front calipers I drilled them out, Why the hell didn't Suzuki put a hole in the calipers in the first place, so you can knock the damn things out. I suppose they think the bikes are only mean't to be riden in Japan "No salt" and all that.
sexysi

[Spanner Man]

Morning all.
A pad pin from a Yamaha XJ900F, or FJ1200 rear has a 5.5mm hex head, you can use these on the dreaded Suzuki rear caliper, although you have to recess the hole on the outside of the caliper slightly to allow the shoulder of the pin far enough into the caliper body. Otherwise you can't get the pin retaining clip through the hole in the pin.
If a pin wont budge, I never mess around, I get the drill out and drill a 3mm hole in the back of the caliper & punch it out. I've done this Hundreds of times and it's not failed me yet!
As suggested, a good copperslip on the tip of the pin is a must, and I've found that tapering the pin SLIGHTLY at the tip is well worth doing.

Cheers.