My GSX1400 Restoration

[steve porter]

Good call then if they were that stuck

[SA14]

I agree.

Plus it didn't help that I forgot to move the pistons while still on the bike as @Hooli suggested. That was the biggest fuck up so far. All the fluid is out of the system now so it'd be a big job to bolt everything back up and bleed the system in order to use hydraulic pressure to push them out but it's not impossible.

First thing I did was release the fluid and remove the lines then cracked the body bolts and before I knew it I had the calipers apart on the bench. That was when I swore about forgetting to push the pistons out using hydraulic pressure. Josh (from here) is going to pop around in a few minutes in case that piston can be salvaged. The good new news is that piston is stuck pretty fast into the bore so it was only bent a bit on the top. If the bore is salvageable I might be able to hammer that small piston straight enough to be used.

While I'm waiting I'm watching those videos again plus a few more I found and the way their pistons come out is a breeze compared to how hard mine are at the moment.

[SA14]

@Throttle came over and took charge. We inspected, ummed, aahed, grunted and swore while pulling pistons (they were in there hard!) but in the end they all came out and inspected ok. Then we bolted it all back up up to perform an @Hooli dance and forced that stuck bastard out. As for the damage, he came up the idea to use a perfectly matched socket as an internal dolly to round up the piston as best I can. I'm a (bit of a) metal worker (in a previous life) so I'll tap it gently and evenly until she's round again then sand (or even file) her smooth and polished and put it all back together.

I'll planish and metal work it so it's as round as possible on the inside but she will probably still have an internal dent which if the outside is round enough should do the trick and no matter as much. Not ideal but it'll be a pushing piston were as before it was definitely a stuck piston. The damage is above the seals (luckily) Seals look ok though a bit stiff but the pistons we cleaned and polish and greased up and re-inserted in order to rebuild the system back up again to push the recalcitrant piston out seemed to come back out again reasonably easy so I have hope again. I'll post a photo or video when I'm happy with the roundness.

Wish me luck, the pistons are hard so if I'm persistent I reckon I'll be able to move the metal back into position.

[grog]

Mate, what a day youve had. 🤞🏻For a good result.

[SA14]

Mate, what a day youve had. 🤞🏻For a good result.

A good day indeed but it's not over yet. I've just finished repairing the dented piston. So now the job starts...lol I have to clean my bench, pull everything apart again, clean everything down then re-assemble. Here's a photo and video of the repaired piston. Even yesterday if you'd be telling me I'd be repairing a dented piston I'd have said you're Biden level crazy. But with encouragement and a visit from the actual forum to my house (!!!) I'm confident to proceed.

I was explaining to @Throttle that this was my first ever brake job and he laughed and said "mate, you picked the most intense brake system of them all to start! Two brains are far better than one and as usual, doggo was of no help what so ever.

and now...some a pic and video!

[grog]

Mate, dont even reckon Barmy had his pistons that shiny. I might be wrong, he prob pulled them out just to polish. 😂

[KiwiCol]

I reckon you're right Grog. 

[SA14]

Mate, dont even reckon Barmy had his pistons that shiny. I might be wrong, he prob pulled them out just to polish. 😂

Haha, I had to get them shiny so I could see the defect but must admit, strangely satisfying.

[SA14]

Ready or not, here I go. I'll install the main seals with the fat edge down into the bore. I'll be smearing everything as I go. Can't believe I'm in this deep. You guys better know what I'm doing because I'm flying by wire.

I'll push the pistons into the vote all the way in as suggested. Bolt the calipers up tight and torque them up once bolted up to the forks. I'll make sure my banjo bolt washers are either side of the banjo. My pad pins are polished and lightly greased. I don't have any antiseize for the caliper body bolts though so I'll just use a smear of regular heavy duty grease. Better than nothing.

Bleeding will be an ordeal but at least I've done that before and have the video above to guide me. I'm a bit worried about all the air behind the pistons though. I'll cross that bride if I come to it.

All this without beer 🍺 too! Probably wise.

[grog]

Will never work without beer😂

[Hooli]

When I said the other bleed nipple I meant the one on the other caliper. A small syringe will do, it'll just take longer.

It doesn't need any pressure to fill it to the master cylinder pot as when the lever isn't pulled the pipe work is open all the way through. The hoses etc are only a sealed system when you pull the lever to pressurise the brake fluid.

The other way is leave both nipples wide open and pour fluid into the master cylinder pot. Once you see it dribble out the nipples it's full enough to bleed as normal.

Looks like you've done well so far.

[SA14]

When I said the other bleed nipple I meant the one on the other caliper. A small syringe will do, it'll just take longer.

It doesn't need any pressure to fill it to the master cylinder pot as when the lever isn't pulled the pipe work is open all the way through. The hoses etc are only a sealed system when you pull the lever to pressurise the brake fluid.

The other way is leave both nipples wide open and pour fluid into the master cylinder pot. Once you see it dribble out the nipples it's full enough to bleed as normal.

Looks like you've done well so far.

Thanks again. I was just reading your syringe post above again and also watched that video again. I'll push the pistons all the way back into their bores so there's no air gap back there. Gravity prime the hoses as well as squirt some in with my syringe through the bleeder holes on both calipers. That ought to get enough fluid in and air out to get me started on the bleed. I also have that Vacuum pump from when I flushed the brakes when I first got it in case I get stuck. @Throttle and I used it to get enough fluid into the system to go back in and push that little piston out. Heading out to re-assemble and bleed. I may even be riding by tonight which I consider totally unbelievable but let's not speak too early.

[grog]

Mate, out of every thread ive ever read here, you win for persistence, having a go and solving. My hats off. Brilliant work. 👏

[gsxbarmy]

Mate, dont even reckon Barmy had his pistons that shiny. I might be wrong, he prob pulled them out just to polish. 😂

you betcha - I even mirror polished the sump @grog - mind you only the once 

[AndyB]

I dont envy you the job of bleeding the 6 potters off....had them on my GSXR  11....tried everything, syringe, vacuum pump,even had them hung upside down from the garage roof....cut a long story...swapped them for a pair of 4 pots..  2 seconds to bleed off....
Also noticed on my 14 when I was looking to buy it & you can see from the posted photos....the six pots have been changed to 4s .....guessing he had the same problems