Tokico 4 pot callipers, got them mostly apart.

If you end up using compressed air ( I used a foot pump ) be careful as the piston is liable to come out like a projectile !

Then how are you going to get the other three out ?

If you end up using compressed air ( I used a foot pump ) be careful as the piston is liable to come out like a projectile !

 

Then how are you going to get the other three out ?

Good point, I didn't split the caliper 1st & pumped em all out with a piece of thin wood between them, then split it & after the 1st one put a dent in my Dads shed roof pulled the others out with grips & a piece of old rubber ( if I'd been on the forum back then I'd have used an old inner tube )

The other option if they are the same tocs as on the busa ( 90mm spacing ) is upgrade to Nissins, has any ZZR owners done this on here ?

Good job, lot os small parts, I usually end up loosing or breaking some of them and at the end after assembly always have spares remaining

Tried pulling out the plastic bit thingy from inside a piston. Came out easily will try the rest later and have a good look.’mbest way of cleaning them up? I think fairy liquid and warm water seems not as effective as what I have watched on a YouTube

Tried pulling out the plastic bit thingy from inside a piston. Came out easily will try the rest later and have a good look.’mbest way of cleaning them up? I think fairy liquid and warm water seems not as effective as what I have watched on a YouTube

Screwfix no nonsense degreaser is really good (and cheap).

I haven't actually found anything in the no nonsense range that isn't any good

The plot thickens...

I got one piston insert out very easily yesterday morning when I had a quick look before going to work. Today I got up early so that I can attack them some more.

All other piston inserts were totally totally stuck. Based upon a mix of optimism and and stupidity and noticing non of the brakes in the YouTube have them I tried drilling a pilot hole, screwing in a screw and pulling.

That did not work, I then stuck a hole either side and made a big flat head screwdriver space and I was able to turn but it turned the whole piston. Great news the piston is out. Not so great news the insert is still in it.

That coupled with what looks to me like scoring on the outside of the piston (maybe caused on the way out but not caused by me being in contact with it) and I thought I would come here for more help.

Help, what do I do to get the piston inserts out? Are they necessary? Do I need to replace the one I have, will I have to replace this and maybe other pistons? Should I just buy some replacement brakes?

Tune in next time.

Oh and should I soak everything in oil? No idea why I think that but hay, random thoughts at half five are sometimes useful.

Piston cleans up. Not scored but with crud on

Is there any reason I cannot remove the rest of the pots the same way? I could repair the piston inserts with plastic weld if needs be although I wonder if I would need to do that?

The plot thickens...

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I got one piston insert out very easily yesterday morning when I had a quick look before going to work. Today I got up early so that I can attack them some more.

All other piston inserts were totally totally stuck. Based upon a mix of optimism and and stupidity and noticing non of the brakes in the YouTube have them I tried drilling a pilot hole, screwing in a screw and pulling.

That did not work, I then stuck a hole either side and made a big flat head screwdriver space and I was able to turn but it turned the whole piston. Great news the piston is out. Not so great news the insert is still in it.

That coupled with what looks to me like scoring on the outside of the piston (maybe caused on the way out but not caused by me being in contact with it) and I thought I would come here for more help.

Help, what do I do to get the piston inserts out? Are they necessary? Do I need to replace the one I have, will I have to replace this and maybe other pistons? Should I just buy some replacement brakes?

Tune in next time.

Tbh james I'd just clean them up as much as you can so long as the one you drilled isn't all burred up then you will be fine using the pistons you already have, and those inserts I would hazard a guess that they are something to do with anti vibration/squeal so they may be needed

If you take the piston seals out put them down the same way up as you took them out. They look practically the same both ways but they do have go in the right way to work.

You will know if you fecked it up as they'll start leaking

Thanks. My current plan then is to create a big flat head hole in each of the plastic piston inserts and that can help me get them out. Ideally the piston inserts would come out but failing that make them flat head holes.

Then I leave them stuck in the piston, clean all of it up so if does not affect performance. Replace all the seals and reassemble.

The pins that the brake pads slot on look corroded, is that a problem?

Thanks. My current plan then is to create a big flat head hole in each of the plastic piston inserts and that can help me get them out. Ideally the piston inserts would come out but failing that make them flat head holes.

Then I leave them stuck in the piston, clean all of it up so if does not affect performance. Replace all the seals and reassemble.

The pins that the brake pads slot on look corroded, is that a problem?

I won’t be doing any more tonight because Mrs in Brum and I got married eight years ago and we need to make time to do something nice or have a row

Give the pins a clean down with a wire brush or similar (maybe not tonight though )

Give the pins a clean down with a wire brush or similar (maybe not tonight though )

Unless its the row you have then you can remove yourself to your man cave like any normal male would

This is where I am at right now...

A few questions. There is an unpleasant patina on the callipers. Is that a problem? If so what do I do?

Do I do some more aggressive cleaning and paint them? If so what with?

Also any advice on what to do next?

I know to remove and replace seals and clean with brake cleaner. It’s the body of the calliper that I am unsure about.

Photos of the callipers after a thorough scrubbing in Screwfix degreaser.

I’m inclined to have a go at the cyclinder (not piston but the hole they go in) with the aerosol brake cleaner and then reassemble. I don’t like that they don’t look like new but I don’t know how to make that happen.

You can spend a few hours with wet & dry to get rid of the oxidation and old paint then give them a fresh coat of paint. Depends how much it bothers you I suppose.

If it is not a necessary job I will do that next time I take them off

That first picture looked bad enough to attack it carefully with a wire brush on a drill then apply satin black as a short term repair till you can do them properly.

Cheers

Ian

Spray satin paint okay or does it need to be high temp?

Halfords does not have DOT 3 break fluid, a quick google says dot 4 is compatible. Any advice?