Oops! brake mistake

[chef1366]

you re right those pistons dont look to good
but wait til you have them out of the calipers and see if they are rusted or pitted in their contact area
outside surfaces can be cleaned and a little brake caliper grease aplied so no new rust is formed
the best though would be to replace the pistons and the rubber seals

Ditto. What we see there doesn't matter. It's the inner piston and caliper that matters.
If you even have a cheapo elecrtric air pump use it on the flat side and pop that piston out. Block the connection to the line and do the same with the other side.

[midnightcafe]

I put the rear caliper back together and pumped some brake fluid into it. The piston outisde the bike came out, while I had to take the other side to the vice and pull hard. Both pistons have corrosion below the seal level, so they're junk.




they may look clean underneath...

but this is the gunk that seized them in the first place.

I could get stainless steel custom fabricated pieces at $32 a piece, but I don't think I'll be needing that kind of material.

QUESTION: would a 'piston set' as seen below (number 1) include just the two pistons?

[midnightcafe]

So I just called three dealerships and one FINALLY picked up. The guy was nice, greater boston motorsports, thank you. He explained to mee that EVERYTHING the number 1 line covers is included in the piston set. That means, shims, brake pads, pistons, seal boot covers, seals, and the o-ring! This is about $33 out of flatout motorcycles. decent deal!

[Nessism]

Including the brake pads? I hope that parts guy is right but for that price, it doesn’t sound right.

Not sure if you ordered already but you might want to take a scotchbrite to the pistons and see what they look like after a little cleanup. The corrosion won’t hurt anything as long as it’s above the sweep area of the piston seal – dust boot sweep area doesn’t matter other than you don’t want to damage the dust seal.

[Suzuki mad]

While you have the calliper apart and sorting that end please check the master cylinder and pivot point on the pedal/frame aslo.

Its worth doing the whole job.

Suzuki mad

[midnightcafe]

Including the brake pads? I hope that parts guy is right but for that price, it doesn’t sound right.

Not sure if you ordered already but you might want to take a scotchbrite to the pistons and see what they look like after a little cleanup. The corrosion won’t hurt anything as long as it’s above the sweep area of the piston seal – dust boot sweep area doesn’t matter other than you don’t want to damage the dust seal.

I did and they still have pitting that catches my finger when i run along it. just ordered the parts, the piston set shows only one required for the bike so it has both pistons included. I thought it dodn't include the brake pads ($44 OEM) but the parts guy said it does. I'll write back when I receive it.

I just checked the rear rotor for wear and shows .264" thickness all around, good shape. Runout is fine.

Suzuki mad, I'll be doing that very soon

[midnightcafe]

So the parts guy emailed me to let me know that there may be a mistake in the parts listings. The total cost of the individual parts would be a little over $90 whereas the piston set only costs about $40. However, he called suzuki and they said that the piston set supersedes the parts listed within the piston set bracket on the diagram. THIS means that I would be getting a great deal on the parts, but It's more likely that the company made a mistake in the parts diagram! I'm sure I'm just buying the pistons but who knows...

[midnightcafe]

Brake parts came in yesterday:

so the piston set is the two pistons, seals, dust covers, and the o-ring. no shims or brake pads as the parts listings suggested. Considering a rebuild kit is $23 off z1-oem brake pistons for $12? that's an excellent deal!

If you ever need to ask a question to the dealership, email this guy:
bob.fuller@greaterbostonmotorsports.com
he's an excellent source of information, unlike other dealers who don't bother repsonding for a week.