Dodgy caliper dust seal, wut do? (Kawasaki ZR-7S 2004)

[NJD]

[NJD]

Need some help please.

One piston is out and the other isn't, the bad one. Dust seals out but fluid seal is holding it in place. Over pumped the OK piston and wobbled loose and realised what had happened, no biggie.

Pop down the local bike shop and ask them to get it out or is there a DIY method. Tried putting cloth around piston and pulling but no luck.

https://s12.postimg.org/5ru51gjfh/image.jpg
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The do it all, T̶h̶e̶ ̶b̶r̶o̶k̶e̶n̶ ̶o̶n̶e̶,̶ ̶T̶h̶e̶ ̶b̶i̶g̶ ̶l̶u̶m̶p̶,̶ ̶C̶h̶o̶n̶g̶ ̶N̶o̶o̶d̶l̶e̶

[chris-red]

[pompousporcup...]

or these:
https://www.amazon.co.uk/Draper-Expert-30838-Motorcycle-Piston/dp/B00487UO1G/ref=sr_1_1?ie=UTF8&qid=1495637520&sr=8-1&keywords=piston+removal+tool

i have used these a few times to get stubborn pistons out. yours looks like its out a decent amount and 'shouldn't' need much more effect.

[DRZ4Hunned]

Can't you just put the piston back in and pump them out again properly?
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DRZ400-SM
FZS600

[chris-red]

[chris-red]

[pompousporcup...]

[NJD]

[DRZ4Hunned]

How much is half the caliper? Doesn't take long to pop the piston back in and re-bleed it...
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DRZ400-SM
FZS600

[kgm]

Use a cut up bit of bicycle inner tube or similar rather than a towel. It'll give more grip and more protection.

[NJD]

I must be the only person in the world who doesn't have a rusty bicycle to steel an inner tube from, typical.

Might try and cut some of that protective crap of the trampoline pole's that serves no purpose. See what it's made out of when I can be bothered to venture beyond my room tomorrow.

Aye, didn't help trying to undo the Banjo bolt after the fluid had leaked everywhere. Slippy as awt. Why I ended up un-doing the other end that attaches to the bike because saved god only knows how long. I was on a good run of about an hour or thereabouts before the piston stopped me in my tracks. Turned into an afternoon of adventure.

Not sure if this ever would have worked but tried using half the bleed pipe attached to the nipple and the other end to my track pump with my finger over the hole inside the where the piston that's out should be and with 20psi I didn't get anywhere, I assume you need both in for that to work. Genius moment I thought, if it would have done what I wanted it to.

Order of the day, tomorrow: (1) try rubber thingy (2) visit local D.I.Y shops and see what's what (3) try putting piston back in and getting the other one out (4) order tool from the internet.

I phoned the local shop and he was like "we're too busy," I don't think he listened to me since he asked what bike it was despite my attempt to tell him I had the caliper in my hand. No wonder I've always disliked the place, potato heads lot of em.

My day dreams of how one day I'll be looking back at this episode once it's all over and wonder why I didn't try the solution first will soon come to an end, oh the mechanical woes I need a lye down <dramatic>.

S'been good fun and I've learned a thing or two at least. Better to crack on tomorrow with a fresh mind though.
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The do it all, T̶h̶e̶ ̶b̶r̶o̶k̶e̶n̶ ̶o̶n̶e̶,̶ ̶T̶h̶e̶ ̶b̶i̶g̶ ̶l̶u̶m̶p̶,̶ ̶C̶h̶o̶n̶g̶ ̶N̶o̶o̶d̶l̶e̶

[NJD]

TL:DR - DONE IT M8.

Deleted post because spanner question, I figured it out. NTS: Rear resivour cap should not look like this and instead should look like this. I'm confusing myself trying to correct myself. Whatever, it's in. I did open the resivour cap again though afterwards just to put the rubber thing back in, pedal felt good still.. probably die next time out.

Head feels funny after all that sun plus sniffing fluids and lubes so leave the test ride until tomorrow.

Anyway since you're half a story behind I got the piston out by phoning up the shop I always use and asked them to have a look, they said they'll sneak me in and when I turned up he come back within a couple of minutes with the piston out. Said he used one of them tools that chris-red linked (LULZ, that link's been edited to £237.00). Was faster to go there than order a set because of cost and delivery date, I'd still be waiting. I popped a fiver in the charity tin and had a chat and went on my way.

Woke up early today and made a few spanner mistakes, the major one being:

https://s13.postimg.org/x1ua1d99j/image.jpg

Turns out brake fluid strips paint, forgot, lulz. I'll ask about repainting it at a latter date if I ever get that bothered. Adds character I reckon.

Anyway back tracking, tubs be handing for a seal and piston lube bath:

https://s30.postimg.org/m0k5x8te9/image.jpg

One clean caliper ready to go back in (probably make some people nervous that there's dirt around but it all do):

https://s30.postimg.org/sr1abr8rl/image.jpg

As for the cause, dunno, could of just been a shagged seal, think this was before put pistons in:

(The barrel, left, has a few scratches and the piston could probably do with replacing at some point but clean as fudge for the most part)

https://s16.postimg.org/aexuxrm9h/image.jpg

https://s18.postimg.org/64l10p5qh/image.jpg

In other news: water and brake fluid make for a lovely decoration (thank fudge for the sun getting rid of it all before I got moaned at):

https://s7.postimg.org/xhyjekn23/PA4.jpg

.. And that's about it.

Ordered 500g of red rubber grease and found out I've probably now got enough to open my own shop after I used about 0.0001% of the tub. Soon depleted my brake cleaner and other fluids, excellent.

Cheers all (e sayz before test riding).
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The do it all, T̶h̶e̶ ̶b̶r̶o̶k̶e̶n̶ ̶o̶n̶e̶,̶ ̶T̶h̶e̶ ̶b̶i̶g̶ ̶l̶u̶m̶p̶,̶ ̶C̶h̶o̶n̶g̶ ̶N̶o̶o̶d̶l̶e̶