Does anybody know: brake caliper piston removal - ZX6R Forum
 3Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 16 Old 04-10-2017, 04:39 PM Thread Starter
Track Star
 
Join Date: Jul 2013
Location: Arizona
Posts: 411

I Ride: '12 zx6r track bike
Does anybody know: brake caliper piston removal

Does anybody know if the brake caliper pistons on the '09-'12 Zx6r can be removed WITHOUT splitting the calipers? I can't find a source with the dimensions of the pistons (just need height) so I'm hoping someone has rebuilt these and has first-hand knowledge. I would really, REALLY, like to not split the calipers....

Last edited by Duc995; 04-10-2017 at 07:56 PM.
Duc995 is offline  
Sponsored Links
Advertisement
 
post #2 of 16 Old 04-10-2017, 05:02 PM
MotoGP Champion
 
sbk1198's Avatar
 
Join Date: Feb 2016
Location: Nebraska
Posts: 4,392

I Ride: '09 ZX6R
Quote:
Originally Posted by Duc995 View Post
Does anybody know if the brake caliper pistons on the '09-'12 Zx6r can be removed WITHOUT splitting the calipers? I can't find a source with the dimensions of the pistons, so I'm hoping someone has rebuilt these and has first-hand knowledge. I would really, REALLY, like to not split the calipers....
From the parts diagram, it looks like no. But why? Do you need to replace it or just get the diameter of it? If you just need the diameter, you can probably pull the brake pad out and look on the back where the piston contacts it. If it was used enough it likely left a nice little circle mark which you can measure. If not, then you can do that with something softer that you put in place of the brake pad and then squeeze the brake.

2007 ZZR600 (sold)
2006 CBR600 (sold)
2010 1198 (parted out across North America)
2013 CBR500R (race bike)
2009 ZX6R (race bike)
2015 R3 (project bike and future race bike)

Sponsors: Vortex Racing, MSM, MTR Cycle

April 2016 and April 2017 6OTM winner!
sbk1198 is offline  
post #3 of 16 Old 04-10-2017, 07:53 PM Thread Starter
Track Star
 
Join Date: Jul 2013
Location: Arizona
Posts: 411

I Ride: '12 zx6r track bike
I need to rebuild the caliper due to uneven pad wear. The bike is a '12 with just under 5k track miles and never exposed to rain (so no visible corrosion), yet I've got the front right caliper's lower/outer pad wearing twice as fast as the three other pads in the same caliper. Cleaning them has made no difference, so I guess new seals are next. I posed a similar question on the WERA forum and about half the responders said they were able to do this job without splitting the calipers (different model bikes) and that if I could avoid splitting the calipers I would save some headaches. If I knew the dimensions of the pistons themselves, then I could determine whether there is enough room to accomplish this. Without measurements I am hoping for someone else's personal experience.

Last edited by Duc995; 04-11-2017 at 06:50 AM.
Duc995 is offline  
Sponsored Links
Advertisement
 
post #4 of 16 Old 04-10-2017, 08:09 PM
MotoGP Champion
 
sbk1198's Avatar
 
Join Date: Feb 2016
Location: Nebraska
Posts: 4,392

I Ride: '09 ZX6R
Quote:
Originally Posted by Duc995 View Post
I need to rebuild the caliper due to uneven pad wear. The bike is a '12 with just under 5k track miles and never exposed to rain (so no visible corrosion), yet I've got the right caliper's lower/outer pad wearing twice as fast as the three other pads in the same caliper. Cleaning them has made no difference, so I guess new seals are next. I posed a similar question on the WERA forum and about half the responders said they were able to do this job without splitting the calipers (different model bikes) and that if I could avoid splitting the calipers I would save some headaches. If I knew the dimensions of the pistons themselves, then I could determine whether there is enough room to accomplish this. Without measurements I am hoping for someone else's personal experience.
Oh I see...so what you really need is the length of the piston to see if it will clear the space inside to pull it out. So why don't you just remove the pads, pump the brake a bit grab the piston and pull as far as it goes. If it all comes out, then you got your answer. If it doesn't, then you still got your answer, just not the one you wanted

I can't say I've ever split a caliper, but I don't get why it would be a headache? Isn't it just a couple of bolts, then they come apart and I imagine there is some gasket inside that will probably need replaced? Or is there something else I'm missing?

2007 ZZR600 (sold)
2006 CBR600 (sold)
2010 1198 (parted out across North America)
2013 CBR500R (race bike)
2009 ZX6R (race bike)
2015 R3 (project bike and future race bike)

Sponsors: Vortex Racing, MSM, MTR Cycle

April 2016 and April 2017 6OTM winner!
sbk1198 is offline  
post #5 of 16 Old 04-10-2017, 08:17 PM Thread Starter
Track Star
 
Join Date: Jul 2013
Location: Arizona
Posts: 411

I Ride: '12 zx6r track bike
The OEM bolts that hold a caliper together tend to be made of inferior materials (think cheese-like) and strip easily, leaving one with a real mess; think bolt still in place but head stripped. If you can get the caliper halves apart, there is only one small o-ring that seals the brake fluid passage between the halves.

I'm sure there is someone here who has gone through this process on a Zx6r.
WERA689 and sbk1198 like this.
Duc995 is offline  
post #6 of 16 Old 04-10-2017, 10:36 PM
ZX6r.com Supporting Member
Supporting Member
 
Indy's Avatar
 
Join Date: Jul 2015
Location: Indianapolis, In
Posts: 1,287
Garage
You said you cleaned them..

But the what in them was left out.. What exactly did you clean.

I will assume the pistons. Would they pump out at the same rate or close to it, could you easily stop any ONE piston letting to let the others catch up.
Would they push in fairly easy?
The pin's threw the pads are clean?

What did you clean them with, last step putting a very thin coating of brake fluid on pistons?

Have to ask,, assuming is the mother of fluck up's.
Indy is offline  
post #7 of 16 Old 04-11-2017, 05:24 AM
MotoGP Champion
 
sbk1198's Avatar
 
Join Date: Feb 2016
Location: Nebraska
Posts: 4,392

I Ride: '09 ZX6R
^There is only 1 piston in the rear caliper.

2007 ZZR600 (sold)
2006 CBR600 (sold)
2010 1198 (parted out across North America)
2013 CBR500R (race bike)
2009 ZX6R (race bike)
2015 R3 (project bike and future race bike)

Sponsors: Vortex Racing, MSM, MTR Cycle

April 2016 and April 2017 6OTM winner!
sbk1198 is offline  
post #8 of 16 Old 04-11-2017, 07:00 AM Thread Starter
Track Star
 
Join Date: Jul 2013
Location: Arizona
Posts: 411

I Ride: '12 zx6r track bike
Quote:
Originally Posted by Indy View Post
You said you cleaned them..

But the what in them was left out.. What exactly did you clean.

I will assume the pistons. Would they pump out at the same rate or close to it, could you easily stop any ONE piston letting to let the others catch up.
Would they push in fairly easy?
The pin's threw the pads are clean?

What did you clean them with, last step putting a very thin coating of brake fluid on pistons?

Have to ask,, assuming is the mother of fluck up's.
Nothing was left out. The pistons were pumped out as far a possible and cleaned with soapy water and a toothbrush, then rinsed with distilled water. There was nothing but dust on the pistons and caliper.

No, the pistons would not pump out at the same rate. The one with the excessive pad wear would always pump out first and the others would only pump out if the one with the excessive wear was restrained. After playing with all of them, and pumping them all back in and out, and using a special tool to rotate them in their bores, things got better, but they never all moved the same.

Yes, the caliper pins through the pads are clean.

No, I did not put a coating of brake fluid on the pistons. After raising the question of putting something on the pistons on the WERA forum, the consensus was not to. That anything applied would attract dirt. If the pistons are pushed into their bores fully, they will coat themselves with brake fluid.
Duc995 is offline  
post #9 of 16 Old 04-11-2017, 08:19 AM
MotoGP Champion
 
riverszzr's Avatar
 
Join Date: Sep 2008
Location: 4 months of frozen hell
Posts: 4,723

I Ride: 86,000+ mile '07 ZZR600
I always split the calipers to do the most thorough job possible...but by looking at them I am sure one could get the pistons out while the caliper is assembled.

I have never had any issue with the bolts that hold the two halves together, I think dumb uneducated people with inferior tools have filled the internet with worries and problems that don't exist for smart people with good tools.
sbk1198 likes this.

Stupid people say stupid things on the internet, so be wary of who those people are. If you solicit advice on the internet, just keep in mind 99% of what you'll receive is not based on fact or science-and likely atleast 95% of it is based on bullshit and bravado regurgitated from some other schlub who also did not experience any of what they claim and are also full of shit. If you don't like my bluntness- too bad. I am not here to please you, so move along, your approval is not desired nor is it needed. So before opening your pie hole and adding more stupidity, perhaps sit back, listen, absorb and learn something. You know that saying, it is better to remain silent and thought a fool than to open your mouth and remove all doubt!
riverszzr is offline  
post #10 of 16 Old 04-11-2017, 08:32 AM Thread Starter
Track Star
 
Join Date: Jul 2013
Location: Arizona
Posts: 411

I Ride: '12 zx6r track bike
Quote:
Originally Posted by riverszzr View Post
I always split the calipers to do the most thorough job possible...but by looking at them I am sure one could get the pistons out while the caliper is assembled.

I have never had any issue with the bolts that hold the two halves together, I think dumb uneducated people with inferior tools have filled the internet with worries and problems that don't exist for smart people with good tools.
So you've done this on your bike? I have a Ducati that I swear the stock hardware is made out of Swiss cheese! The hex head caliper bolts immediately stripped out prior to unscrewing from the calipers, requiring the bolt heads to be drilled off, and extreme difficulty in extracting the bolt studs.
Duc995 is offline  
post #11 of 16 Old 04-11-2017, 10:39 AM
MotoGP Champion
 
sbk1198's Avatar
 
Join Date: Feb 2016
Location: Nebraska
Posts: 4,392

I Ride: '09 ZX6R
Quote:
Originally Posted by Duc995 View Post
So you've done this on your bike? I have a Ducati that I swear the stock hardware is made out of Swiss cheese! The hex head caliper bolts immediately stripped out prior to unscrewing from the calipers, requiring the bolt heads to be drilled off, and extreme difficulty in extracting the bolt studs.
Most bolts on motorcycles that are made out of stainless are soft. Stainless steel is soft in general, unless you get into the more exotic types, but the stuff you find at any hardware store (which I'm guessing is similar to what OEM's use) are soft. That's why it's important to have the right tools and to not over-torque things. I get your frustration though, I've been in that situation a few times, but every time it was either my fault or the person that worked on it before. It was never the bolt's fault.

Also, a thing to keep in mind about the WERA forum...although it can be very helpful due to the large amount of people on there, a lot of BS also goes along with that large number of people. Every time I post a thread on there, it ends up being 20-25% of the comments that are actually helpful, the rest is people BS-ing around about irrelevant shit.

Edit: and why the hell is it called "the beebs" or "BBS"?? Where does that come from?? Still haven't figured out the story behind those nicknames.

2007 ZZR600 (sold)
2006 CBR600 (sold)
2010 1198 (parted out across North America)
2013 CBR500R (race bike)
2009 ZX6R (race bike)
2015 R3 (project bike and future race bike)

Sponsors: Vortex Racing, MSM, MTR Cycle

April 2016 and April 2017 6OTM winner!
sbk1198 is offline  
post #12 of 16 Old 04-11-2017, 11:34 AM
MotoGP Champion
 
riverszzr's Avatar
 
Join Date: Sep 2008
Location: 4 months of frozen hell
Posts: 4,723

I Ride: 86,000+ mile '07 ZZR600
Quote:
Originally Posted by Duc995 View Post
So you've done this on your bike? I have a Ducati that I swear the stock hardware is made out of Swiss cheese! The hex head caliper bolts immediately stripped out prior to unscrewing from the calipers, requiring the bolt heads to be drilled off, and extreme difficulty in extracting the bolt studs.

I have worked on motorcycles for a living since 1982

I have done this to hundreds of bikes including more than a few Douchecatis...but I thought the question was about 09-12 ZX6R?

Stupid people say stupid things on the internet, so be wary of who those people are. If you solicit advice on the internet, just keep in mind 99% of what you'll receive is not based on fact or science-and likely atleast 95% of it is based on bullshit and bravado regurgitated from some other schlub who also did not experience any of what they claim and are also full of shit. If you don't like my bluntness- too bad. I am not here to please you, so move along, your approval is not desired nor is it needed. So before opening your pie hole and adding more stupidity, perhaps sit back, listen, absorb and learn something. You know that saying, it is better to remain silent and thought a fool than to open your mouth and remove all doubt!
riverszzr is offline  
post #13 of 16 Old 04-11-2017, 11:36 AM Thread Starter
Track Star
 
Join Date: Jul 2013
Location: Arizona
Posts: 411

I Ride: '12 zx6r track bike
BBS is an acronym for "bulletin board system," which seems to refer to the early beginnings of online forums. "Beebs" is just saying it the way it appears...

There is a lot of BS on the WERA forum, but as you said there are many with extensive professional experience in all walks of life.
Duc995 is offline  
post #14 of 16 Old 04-11-2017, 11:39 AM Thread Starter
Track Star
 
Join Date: Jul 2013
Location: Arizona
Posts: 411

I Ride: '12 zx6r track bike
Quote:
Originally Posted by riverszzr View Post
I have worked on motorcycles for a living since 1982

I have done this to hundreds of bikes including more than a few Douchecatis...but I thought the question was about 09-12 ZX6R?
I didn't know a thing about your professional experience, and yes, this question refers to my '12 Zx6r.

I just wanted someone - like yourself - to say "yes" or "no" that they had personally extracted a front caliper piston without splitting the calipers.

I greatly respect your knowledge and experience...
Duc995 is offline  
post #15 of 16 Old 04-12-2017, 01:30 PM Thread Starter
Track Star
 
Join Date: Jul 2013
Location: Arizona
Posts: 411

I Ride: '12 zx6r track bike
...that being said... I am surprised nobody on here has tried this. Personally, after looking at the calipers I don't think there is enough clearance for the puck and an extraction tool to fit during removal. Also, I would think it would be difficult to accurately remove and install the seals with the calipers intact. I'll return to this thread and report my results when I gets the parts I need and give it a try.
Duc995 is offline  
Reply

  ZX6R Forum > ZX6R Forum > Mechanical and Technical

Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
brake pad change - lubing caliper pins GEB Mechanical and Technical 4 06-10-2016 12:28 PM
Brake caliper new seals or resuse Gw11aas The ZX6R 3 04-14-2016 01:25 PM
Brake Caliper Seals ZX6RCol The ZX6R 4 04-14-2009 05:30 AM
brake pad springs 03 B1 anyone got a photo of front caliper???? damonkeh13 The ZX6R 4 03-26-2009 05:30 PM

Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome