Front Caliper Rebuild ( again )

[SSGT_B]

As most know I recently did new rotors, HH pads, new SS lines, RCS19 master and a deep cleaning on the calipers reusing the seals. No matter how much bleeding I did the brakes although slightly better, still felt lacking. So I ordered a new seal kit from brakemasters and decided since everything else was new, I’ll throw new seals at it too. Worse that can happen is the brakes still suck. Today I took them apart and found a few interesting tid bits. The pistons were not moving equally and they were a bear to get out. Had to use the air gun to pop one. A few seals were “tweaked”. After the new seals were in I used brake fluid to lube them and the pistons and the pistons slid back and forth like melted butter. After a good bleeding I have the lever tied off for the night. I’ll bleed them again tomorrow then hopefully off to test them.

 

[SSGT_B]

 

[c10]

practice makes for perfect

 

[WuzzaCBXRider]

I must be living a charmed life as I’ve never done anything to my brakes other than adding new HH pads and after 65,000 miles, new Arashi rotors. However, IME replacing anything that included a seal, it was always a good idea to replace the seals with new ones whether it be wheel bearings on a bike or car or wheel cylinders. Hope this works out.

 

[Kiwi Rider]

Great work Sarge, I'm super curious as to whether this will improve the lever feel and braking force.
I'm going to do the same to my calipers soon, but my '99 Tokico calipers have 2 transfer ports, one at the top like yours has . .and one at the bottom too. So when it comes time to buy the seal kit I'll have to be sure there's 2 of those little seals for the transfer port, per caliper.

 

[Berlin Germany]

hey sarge - yes super nice work (wonderful pics)

i´m so much with you - million percents

the damn folded dust gasket, which "stops" the piston - i found that also at lots of "tokico" calipers (factory stand)
the white (sanitary teflon ?) band round the bleeders thread
the deep cleaned calipers
cleaning the threads

but the (main) m12 caliper screws never need thread lock - if tightened with 39 Nm they never can come loose.

i hope you don´t use the "lock" for the allen screws at the front fender (and so)
that can end up super shitty, when the allen turns through (and is destroyed) while you´re trying to loosen it again.
i met this damn situation 3 times now and the resulting use of a drilling machine is really not very funny.
the danger of a breaking front fender holder (only pencil thick) is always there and then the fork leg is more or less for the rubbish bin.

I personally only use the "locker" where the manual specifies.

 

[ZeePopo]

So the folded dust seal was what created the problem? I cleaned my calipers pistons recently since I felt not all the pistons are moving properly. But then a short time after they started not fully extending. Barely have 10k miles on the new bird. Maybe I should remove the pistons and inspect the dust seals.

 

[c10]

You gen 1 guys need a set of these for piston removal. Good friend Pete on the ZRXOA makes these from welding pliers .
Best way to remove any piston on split type calipers.

 

[SSGT_B]

Great work Sarge, I'm super curious as to whether this will improve the lever feel and braking force.
I'm going to do the same to my calipers soon, but my '99 Tokico calipers have 2 transfer ports, one at the top like yours has . .and one at the bottom too. So when it comes time to buy the seal kit I'll have to be sure there's 2 of those little seals for the transfer port, per caliper.

There are extra seals in the kit for both crossovers as well as extrA bleeders Incase you have 2 on each caliper

The Teflon I put on the bleeders so as to not draw in air around the threads while using a vacuum pump.

Only put blue loctite on the caliper mounting bolts.

 

[SSGT_B]

You gen 1 guys need a set of these for piston removal. Good friend Pete on the ZRXOA makes these from welding pliers .
Best way to remove any piston on split type calipers.

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Those would have come in handy!!

 

[SSGT_B]

This morning I bled the master and both calipers. Got 1 bubble. Not bad. Preparing for the test ride but I can tell you now, less lever travel and it is solid! No squish after the initial stopping of the lever. I took a pick of the lever travel from the outside of it.

 

[fallenarch]

Really awesome write up! I know how much extra effort this is to do so thanks very much for taking the time. BTW: Did you try adjusting the ratio on the RCS? My RCS 19 was perfect on the brake side but I had to find the sweet spot on the clutch side.

 

[SSGT_B]

Really awesome write up! I know how much extra effort this is to do so thanks very much for taking the time. BTW: Did you try adjusting the ratio on the RCS? My RCS 19 was perfect on the brake side but I had to find the sweet spot on the clutch side.

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Thanks @fallenarch I will be trying the adjustments now that it feels right. Tried before and was still blah. That said, just took it for a short 20mile ride..........

1finger panic stops are achievable easily!!! Would be scary if you did not expect it. The brakes now remind me of my 1000RR. Very happy. Now I might just rebuild my rear caliper for giggles...lol

Edit, just ordered the rear rebuild kit from Brakecrafters. 30 bucks after discount code and shipping I figure is good insurance.

 

[Kiwi Rider]

Thanks @fallenarch I will be trying the adjustments now that it feels right. Tried before and was still blah. That said, just took it for a short 20mile ride..........

1finger panic stops are achievable easily!!! Would be scary if you did not expect it. The brakes now remind me of my 1000RR. Very happy. Now I might just rebuild my rear caliper for giggles...lol

Edit, just ordered the rear rebuild kit from Brakecrafters. 30 bucks after discount code and shipping I figure is good insurance.

Ok, that’s it!!
I’m getting me a set of brand new caliper seals!!
But sadly, I have to put up with a crappy OEM m/cyl dang it.....

 

[michael parris heuberger]

Ok, that’s it!!
I’m getting me a set of brand new caliper seals!!
But sadly, I have to put up with a crappy OEM m/cyl dang it.....

HI. Why not just get a Brembo RSC 17/19 master and a set of used Brembo calipers. That can not be that much $.

 

[Kiwi Rider]

HI. Why not just get a Brembo RSC 17/19 master and a set of used Brembo calipers. That can not be that much $.View attachment 1617310

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Wow . . . you showed us your bike!!! COOL ! !
A brembo RCS19 would cost me a lot, take the $US price and double it for the $NZ price, then add freight and 15% for our taxes here at border entry, and you can get an idea of why I've been putting it off lol.
Re the brembo calipers, that would be $heaps as well, then add the caliper mounting brackets needed for the Gen 1 forks . . . plus . . I need new rotors as well!
So, it adds up to way more than I can afford at the moment, I'm on 80% wages and just making ends meet.

On a side note . . why do you use so much purple color on your bike?
favorite color? Bought the paint at a cheap price?
I'm not a fan of the color, but I do like your bike set up!

 

[mabupa]

Thanks @fallenarch I will be trying the adjustments now that it feels right. Tried before and was still blah. That said, just took it for a short 20mile ride..........

1finger panic stops are achievable easily!!! Would be scary if you did not expect it. The brakes now remind me of my 1000RR. Very happy. Now I might just rebuild my rear caliper for giggles...lol

Edit, just ordered the rear rebuild kit from Brakecrafters. 30 bucks after discount code and shipping I figure is good insurance.

This is the type of comment I would expect to see from someone that installs a brembo MC on a busa. Glad to see you got her all figured out. I love mine and even brake more aggressively than I need to, just to enjoy that braking power. I can honestly say I enjoy braking, as much as, I enjoy accelerating my busa. Lol! It’s amazing how fast she comes to a stop.

 

[michael parris heuberger]

Wow . . . you showed us your bike!!! COOL ! !
A brembo RCS19 would cost me a lot, take the $US price and double it for the $NZ price, then add freight and 15% for our taxes here at border entry, and you can get an idea of why I've been putting it off lol.
Re the brembo calipers, that would be $heaps as well, then add the caliper mounting brackets needed for the Gen 1 forks . . . plus . . I need new rotors as well!
So, it adds up to way more than I can afford at the moment, I'm on 80% wages and just

On a side note . . why do you use so much purple color on your bike?
favorite color? Bought the paint at a cheap price?
I'm not a fan of the color, but I do like your bike set up!

Hi. Yes purple is one of the colors I like. The bike will be white with purple pearl in the front and purple pearl in back hard to explain. The paint on the bike now on OE body work

The first skull will be coming out of an Ace of spades [name of my Viet Nam bird The Killer Spade] where it is blue it will be purple main color then some blue and some pink. The back skull will be gone. Replaced with what is on my helmet. The back half will be a dark purple pearl that will go from purple to blue. The tail, stop and turn lights will be under the paint. I have a 3 way head light switch. all the lights will be LEDs The mirrors and front turn light will be built in to the front 3/4 fairing.

Wow . . . you showed us your bike!!! COOL ! !
A brembo RCS19 would cost me a lot, take the $US price and double it for the $NZ price, then add freight and 15% for our taxes here at border entry, and you can get an idea of why I've been putting it off lol.
Re the brembo calipers, that would be $heaps as well, then add the caliper mounting brackets needed for the Gen 1 forks . . . plus . . I need new rotors as well!
So, it adds up to way more than I can afford at the moment, I'm on 80% wages and just making ends meet.

On a side note . . why do you use so much purple color on your bike?
favorite color? Bought the paint at a cheap price?
I'm not a fan of the color, but I do like your bike set up!

Hi. Kiwi Rider.

 

[Bumblebee]

Hi. Yes purple is one of the colors I like. The bike will be white with purple pearl in the front and purple pearl in back hard to explain. The paint on the bike now on OE body workView attachment 1617410

View attachment 1617410
The first skull will be coming out of an Ace of spades [name of my Viet Nam bird The Killer Spade] where it is blue it will be purple main color then some blue and some pink. The back skull will be gone. Replaced with what is on my helmet. The back half will be a dark purple pearl that will go from purple to blue. The tail, stop and turn lights will be under the paint. I have a 3 way head light switch. all the lights will be LEDs The mirrors and front turn light will be built in to the front 3/4 fairing.View attachment 1617416

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Hi. Kiwi Rider.

View attachment 1617411

You need to get a helmet painted with a Huey dust off on it vice that BlackHawk now....

 

[michael parris heuberger]

You need to get a helmet painted with a Huey dust off on it vice that BlackHawk now....

Hi. I bought that Arai helmet in an 2nd hand store for $20.00. A girl in New Bedford Ma. does raps she only had that 1 photo of a helo so for $25.00 I tried it. To me I never liked raps and I still do not. I will have the next one painted on.