Sticking brakes on Suzuki GSR 600

[hopoffbaby]

Hi All,

I have recently brought myself a bike after a few years off. A Suzuki GSR 600.

I went for a ride today and noticed that the bike was difficult to push and after riding the right front brake disk was hot. The rear was pretty warm too.

I seems like the brakes are sticking. Does anyone know how I can fix this, with instructions if possible (that a mechanical noob can follow)?

Thanks,
hopoffbaby

[RhynoCZ]

Take the calipers off, take off the pads, push the pots out a bit (not too far) with the MC (master cylinder = brake lever/pedal). Give it a proper clean. The pots must be shiny clean. If you've got floating calipers, clean the rods on which the calipers float and lube them. You can also check the pots work just fine, when you apply brake pressure, they should get out and then back a bit. If they don't do that, keep cleaning them. If still not working properly, pop the pots out, check the seals in the caliper.

For visual help, check youtube.

To clean the pots, be careful what you use. There shall never be anything that ruins the rubber seals. I use chain cleaner, that was designed not to damage the O rings in the chain. Don't use WD40, it'll swell the seals.
____________________
'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor

[hopoffbaby]

Thanks for the reply. I'll give it a try.

Couple of questions:

1: How can I tell if I have floating callipers or not?
2: Will popping the pots (pistons?) out require refilling the brake system or anything?

Cheers.

[RhynoCZ]

1: if there are only pots/pistons on the one side of the caliper, than it is a floating caliper.

2: no it won't, you are going to have to push the pots/pistons back in, so you could fit it back onto the disc with the pads in. In fact, push the pots/pistons all the way in, once you're done cleaning them.

NOTE: checking pictures of various GSR 600 motorcycles, all of them have solid 4 pot/piston calipers (not floating). Also, to push the pots/pistons back in, you should be able to do that with your bare hands. Don't use tools unless it's necessary. Some people would make dents in the pots/pistons trying to fiddle there with a pliers.

NOTE II: (Safety hazard!!!) Before you go riding after this procedure, push the lever/pedal several times before you go, to push the pads onto the discs again. If you don't do that, the first squeeze of the brake lever/pedal won't do a thing.
____________________
'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor

[Fizzer Thou]

I bought one of these from Hein Gerickes when they were only £20 or so and are useful when pushing caliper pistons back in so as to replace brake pads.

https://www.machinemart.co.uk/shop/product/details/040815180-2

With tandem twin piston calipers you can get away with a 'G' clamp.

But if the calipers have not been serviced and the pistons are sticking because of corrosion behind the seals,the only way to do the job properly is to remove all of the pistons and seals and to do a thorough cleaning of all of the component parts.

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150816_175345_zps3g6szlth.jpg

DOT4 synthetic brake fluid is only £3 for a 500ml bottle from Asda so it will not be expensive to flush and bleed the brake system afterwards,especially so if it has never been done previously

Plenty of useful videos on youtube
____________________
Just talk bikes.What else is there?

Always have a 'Plan B'

[hopoffbaby]

Ok,

So I have got a quarter of the way there lol.

I have one of the front callipers off.

Of the 4 pistons only 1 would move. I have cleaned it up using brake cleaner and a toothbrush and now the bottom 2 in the picture move freely.

The top left one will come out (if I put something in the way of the bottom 2 to stop them moving out) but I can't get it back in now.

The top right one doesn't seem to want to move at all.

Any tips on how to get the pistons back in (I wont be able to get a proper tool to do that until later in the week) and how I can free off the on that doesn't seem to move?

Thanks,
hopoffbaby

[hopoffbaby]

[RhynoCZ]

Mount the calipers back on your motorcycle with no pads in them. Tighten the calipers there. Then loosen up every single bolt that you are going to want to take off. Spray the bolts in the caliper with penetrative oil if you've got some. Then take off the caliper and get the pots/pistons out first, before you split the calipers.

NOTE I: Before you take the calipers apart, loosen up the bolt that holds the hose in the caliper (not too much), then push all the pots out, with the MC (brake lever/pedal).

NOTE II: When you split the calipers, there will be one or two rubber O-rings, between the two halves of each caliper, do not lose those O-rings and put them back when you're gonna re-assemble the calipers.

Own experience: There's no way you'd be able to loosen up the bolts in the caliper, holding the caliper in your bare hands and since there's the hose attached to it, you can't use a vice to hold it. So as I've said, loosen up everything, that you want to take off, before you take the caliper off the fork.

Changing the seals is easy, just make sure the calipers, especially where the seals go, are clean as a whistle. The pots/pistons must be shiny clean, no dirt/brake dust ''baked'' on them! Do not try to use tools that would make dents or scratches on the pots/pistons on/in the places where the seals go.
____________________
'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor

[hopoffbaby]

Right, so to be clear before I do it:

- callipers back on bike, no pads
- pump brake until all pots are touching the disk
- loosen all bolts (after lubing them up good)
- take calliper off bike

- pump brakes until the pistons pop out? (Do I need to do anything to stop some coming out before others?) Will they actually come completely out of the assembly at this point or will they need persuading later?

- keep the o rings.
- clean and put back together.

Will I need to replace the other rubber seals behind the actual pistons?

[RhynoCZ]

1, calipers back on bike (with no pads)
2, loosen up all the bolts + the bolt that holds the hose (not too much)
3, calipers off
4, push the pots out with the MC
5, split the caliper

PS: Have some rags over the wheel and tyre, there will be some brake fluid spilled.

PS: Yes, stop the pots that are quicker than the rest, to get them all out at the same time. Those that don't want to go out are seized and once there's no pressure in the system, you're fecked. The pots/pistons will pop out on their own. Do both calipers (if you've got 2 calipers on one wheel) at the same time.

The seals behind the pistons: will see about that. In the pictures the dust seals are gone.

These are the inner seals (they shall be nice and smooth - not like in this picture):
https://i970.photobucket.com/albums/ae184/RhynoCZ/ZX7R/DSC_0098_zpsea92db1a.jpg
____________________
'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor

[hopoffbaby]

Thanks for all the help. I appreciate it. Forgive my noob-ness.

Im still not clear on how the actual pots come out. I have read on some sites that if one comes out before the others then you'll not be able to get the other 3 out. Is this the case or will the others still move after the first comes out (or can they just be man handled to get them out)?

[hopoffbaby]

[RhynoCZ]

Yes, that is true. Just put a screw driver or something between the pots to stop them before they pop out. Get all the pots as far as they can go (to touch the screw driver or any obstacle).
From that point, you're gonna be able to pull them out with your bare hands. From my experience the pots can go slightly over the ''center line'' of the caliper before they pop out.
____________________
'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor

[RhynoCZ]

[hopoffbaby]

Right I think I'm following now. I'll try this in the morning.

I think the rubber seals are what is jamming the pots now, or at least contributing. So I guess these could be cut off/sliced to help the pots come out.

Regarding the actual cleaning of all the parts, should I be soaking the bits in white spirit or similar?

[RhynoCZ]

No need to soak them, you could, but there's no need really. I just used a brake cleaner, a tooth brush and a clean cloth. No water, although you are going to ''flush'' the calipers with fresh brake fluid once you fit them back on your bike.

Bleeding the brakes will be our next topic, I guess.
____________________
'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor

[hopoffbaby]

[hopoffbaby]

Progress update:

So I have the callipers off and split. I have half the pistons out but I don't seem to be able to get the other sonofabitch pistons out. Some of the rubber seals are coming out too. I have cut 2 of them and pulled the seal out.

Any ideas on how to get the others out?

[RhynoCZ]

Try more pulling force, step on the caliper if you have to (if you can't fix it in a vice) to hold it down while you're pulling the pots. Put something soft under the caliper, so you won't scratch it.

IF you will get to a point where you would need to use a pliers, I suggest to put a rag or something where the pliers will touch the pot and don't just pull on one place only. Go around, one millimeter at the time.

Looking at the pictures, the pots are nearly out, as they are. It shouldn't require too much pulling now.

EDIT: If you have a vice, don't put it there just metal on metal, use some wood or anything to keep it from scratching.
____________________
'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor

[hopoffbaby]

So after praying to the gods, and summoning super human strength I am now the proud owner of a bag of bits.

Now to clean it up. Yay....

The dust seals are fecked, the oil seals look ok to me but i guess they only come in sets?

[RhynoCZ]

Cool, I knew you could pull this off.

I would just get the whole kit for both calipers and do all the seals. It's not that expensive and since you've got so far, why wouldn't you. Remember, everything must be shiny clean and smooth once you're done.

By the way, looking at the picture, you are missing one washer from the bolt that holds the hose in the caliper. There are supposed to be 2 washers, one goes under the hose and the other one above the hose when you put the bolt there.
I can see only 3 ''silver'' washers there.

EDIT: I might be wrong, if it's the 1 hose from the MC directly to 1 caliper and one short hose from the caliper to another, then there might be just 3 washers.

See no. 4 - there are 5 washers.
https://www.motolights.cz/pd/picown2/417901.png
____________________
'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor

[hopoffbaby]

There are 5 washers in total.

2 are still on the bolts and then I have the other 3. There is one cable coming from the master cylinder to the calliper on the right hand side and then a small brake line that goes over the wheel to the left hand brake calliper.

I'll have a look around the bomb site that is my bike but i think I got it all...

[RhynoCZ]

Yep, 5 washers is correct. Make sure you put them there as they were, the brake could leak otherwise.
____________________
'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor

[hopoffbaby]

Phew,

Where did you get the diagram btw?

[RhynoCZ]

It's a Czech site with parts of all sorts. www.partsdepot.cz
The diagram should work for GSR600 2006-2010. In fact, there are far more motorcycles with the same brake calipers and brake hose setup.

Also worth seeing: 03 - SEAL SET,PISTON 59100-35820 (you are going to need 2 sets, obviously)

https://www.motolights.cz/pd/picown2/417899.png
____________________
'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor