How To - Refurbishing Brake Calipers

[Del]

I reckon I have refurbished well over 50 set of calipers and this is how I do it - hope its of some help

Strip the calipers down to all separate components

Bodies – I clean in thinners to get brake fluid out, remove grease and some of the grime
I then used a bench mounted fine wire wheel to remove the rest of the detritus and the old paint – once clean I mount the caliper halves in a vice and using a Dremel with a wire wheel I clean to piston seal grooves to remove the build up of corrosion (it can be fairly hard so persevere here to make sure you get a good clean surface so the new seals sit where they should do)

At this point I run a tap down all the threads to clean these out

Now wipe down with panel wiper (or thinners) to make sire clean

Masking – I mount in the vice again (soft jaws) and place masking tape over the mating and piston holes – the overlap of the masking tape I remove with a very fine file or scalpel

Painting – I sit the caliper halves on rattle can lids – I use a base coat to spray 2 or 3 light coats over the inside and outside faces of the halves – leaving a few hours to cure

If your using rattle cans you may need a few more coats to get a decent build up

Tokico Raised Lettering – to remove the paint from the raised lettering I place 2 layers of masking tape around the lettering and then using a fine flat file I lightly remove the paint – once paint all off a light brushing with a Scotchbrite pad to get a machined look – Wipe again with panel wipe –(not thinners as thinners will remove paint and your back at square 1)

Clear Coating/Lacquering – same principal as the painting – I use a 2K clearcoat applying 2 light coats until I get desired finish – don't go to heavy on the lacquer as it tends to come away in the bolt holes when torqueing up
Of using rattle cans then this is a lot thinner than using the spray gun so may need a few more coats
(I now have the caliper halves vapor blasted as gets them so clean they are ready to paint)

Pistons – I clean in thinners and if the pistons are steel ones, I lightly remove any grime on the bench mounted wire wheel – If alloy ones no abrasives as this removes the coating - if any of the pistons are badly scored get a replacement at this time because if you use a scored or pitted piston you will just wreck the seal

Rebuilding – Placing all you need for one caliper on a clean towel – then using red rubber grease give the seals a light smearing and put into the groove – any remaining grease on your hands wipe on the piston and inset the piston making sure it is level as this makes it go in smoothly – repeat for all 6 pistons

Put the 2 halves together and put in all the half bolts until tight – I torque up on a jig I made to 25Nm or you can wait till the caliper is on the fork leg an then torque up

Caliper is now ready to refit

Hope this helps

Del

[KiwiCol]

@SA14

[SA14]

Thanks @😎KiwiCol.

Just did my first rebuild today. Kind of wished I'd painted them but the caliper paint at the shop was the wrong gold so I proceeded and left the old paint on. Some great tips here @Del thanks for the write up. Got some pics for us? What paint do you use? I doubt we'd have the same brand down here in the colonies but I'd like to eventually spruce them up. Wire wheel inside the grooves was something I didn't think of but mine looked pretty clean, gave them a light going over with a small brass wire brush. Hopefully they'll do the job and not leak. I'll know soon enough I guess.

[Athelstanexxx]

For whom, like myself, preferring an outsourcing rebuild, let me mention here the guys at POWERHOUSE, accidentally found on eBay, but with a pretty website
https://www.powerhouse.uk/content/motorcycle-brakes/motorcycle-brake-caliper-rebuild-service.php

I am planning to forward my calipers to them and have them refurbished and painted

[nod]

why not send them to Del,,,top of this page,,
top job by him,,

[seth]

That's where mine will go @Del
His work is top notch .
Just to add he's one of us .

[mlivkovich]

After great and detailed description it would be shame not to mention to put seals (little o-rings) between halves before assembling

[GSXKING]

@VladTepes taking notes  

[VladTepes]

   

[Athelstanexxx]

I am of course interested in contacting Den for my Calipers yet to be restored.
Do you have a website? Thank you

[gsxbarmy]

I am of course interested in contacting Den for my Calipers yet to be restored.
Do you have a website? Thank you

@Del

[seth]

@Del
Does his refurbs as a hobby just pm him he's normally on here fairly often 

[Eric GSX1400K3]

I am just about to refurbish my K3 caliper including a new seal kit  I have found this kit through ebay.

Am I correct in assuming this is the one most people use?

https://www.ebay.com.au/itm/150958308691?mkcid=16&mkevt=1&mkrid=705-154756-20017-0&ssspo=hS1wkmtVSpa&sssrc=2349624&ssuid=_M0J_4k6R_O&var=&widget_ver=artemis&media=COPY

For us in the colonies, there is also Mick Hone, however their kit is a bit dearer, then again they are genuine Suzuki parts, the UK supplier uses oem spec, which is different than genuine.

I am tempted to do the rear at the same time. I have not yet serviced these callipers since I've owned this bike.

I will do the disc bobbins at the same time

[froudy]

@Eric GSX1400K3

I definitely wouldn't bother with the overpriced ones!
Powerhouse kits are very good and recommended too.

[Speedy1959]

On my last GSX (Old Sophie) I ordered from Powerhouse the set of 4 piston calipers to do the mod I did..
Very nice quality and no complaints so I would think their kits will be well up to standard.

S.