400 Tokico Front brake rebuild

[Uncle Bob]

I think I am correct the front brakes are the same as fitted to other period bikes like the RGV250?

I am going to overall them with Stainless pistons and found this complete kit
https://www.ebay.co.uk/itm/Suzuki-RGV-2 ... 0831488682

That should be OK? They are OEM seals (which the page says are very good quality) - checking the Suzuki prices for Suzuki ones you are looking at £60 for a set just for seals. I did get OEM from Yambits for the TZR and I could not get the piston past the dust seal, the piston seal was OK though. In the end I reused the old dust seals as they did look OK, so not sure I should try OEM again or not.

Anyone else used Powerhouse who are the seller?

Tips on removing the pistons - do I need to split? I think Fossie maybe an expert from his 400 dispatching days.
Is it worth getting a piston removal tool (I do like an excuse for new tools!).

Thanks

UB

[fossie]

Tokico front 4 pot brakes
Getting stainless Pistons , genuine seals are better but red grease is a must.
As for getting Pistons out. A tool may be useful but that wasn't my experience The best way is is split them and use an airline to blow them out , make sure they come out together otherwise you end up pulling the stuck one.
Replace the brake lines with 2 straight to calipers hoses , this makes bleeding up easier and more effective.
Good luck.......these damned things are fitted to my work Bandit Just to haunt me!

[Uncle Bob]

Thanks for that. I already did the lines when I got it about 4 or 5 years ago.
Your little line of icons don't inspire confidence!
I'll probably get a tool just to see what they are like (research for future Pride article is the way I will look at it), and go the splitting route.

I know I should go genuine seals but £60 for 8 rubber rings...

UB

[fossie]

Yep £60 for rubber rings .....try Kawasaki zzr 600 they are the same . You will only do the job once , you should get 16000miles The pads will last 8000 miles , so 2 changes. before you need to replace the seals.......they are affected by grime being pulled in from the brakes and road......old style Kat ones with rubber boots last forever.

If you must go for the tool don't bother with the pliers type, they don't get enough grip on the piston in such a confined area , they are designed for cars ...not multi pis toned bikes . https://www.wemoto.com/parts/picture/sq-ms162
Is the better option.
If you bleed them up and still have a spongey feel or it feels like they still need bleeding it'll be the smaller Pistons moving out slightly after the larger ones, live with it for a while , once the pads have shaped to the disc the pressure with even the 4 out ......or try try try again , swear a lot , try some more , curse some more , then live with it.

[johnr]

the thing is with these that you need to be careful what brake fluid you use. older dot 3 type brake fluids are quite flammable. i mistakenly got some dot 5 brake fluid and its completely impossible to set it on fire. in the end i resorted to petrol and that destroyed it all nicely.
all these little tips are handy to help keep the 250 and 400 kats where they belong...
in smouldering piles of ashes on the pavement......

[Uncle Bob]

the thing is with these that you need to be careful what brake fluid you use. older dot 3 type brake fluids are quite flammable. i mistakenly got some dot 5 brake fluid and its completely impossible to set it on fire

I started reading that and honestly I got to the point of " Oh John is being helpful about the 400..." when...

Love these comments through the 400 threads - anyone new here would wonder about them though... It's like "The Teapot" comments that used to pick on unsuspecting (generally American) GSX600 Katana questions on the old KatanaCentral forum.

Teapot? Where are you now?

[pookie]

People use T bags these days

[Uncle Bob]

People use T bags these days

If you never visited the KatanaCentral forum back in the 90's early 2000's then you will have missed The Teapot, his sarcasm and general demeanour towards the US GSXxxxF owners was legendary!

I never did find out who it was.

[johnr]

i think pookie is nostalgic for the old days when teabagging was easier to procure.........

[pookie]

Definitely showing my age, I still cringe when I see a GSX 600 / 750 / 1100F with the legendary words 'Katana' on its tail piece, even worse is the AY 50 moped scooter thing with the name emblazoned on it, just noticed that there is are cheap Chinese cars with an MG badge on them, AAAARRRRGGGGHHHH