Delboy's Garage, Hayabusa day 13, "Tokico 6 Pot Caliper Rebuild"

[@g40will]

Love that trick with the socket and extension to get the pots out.

[@CajunGreenMan]

That one blew my mind as well!

[@diyhell8712]

Watched the video this evening and had to use the socket trick straight away on my classic cars calipers - great trip!

[@hhoefs83]

@@CajunGreenMan Yeah!!!

[@tonymontana897]

I was thinking the exact same thing lol.

[@odgeUK]

This trick has been a revelation on my own rebuild. Mine were seized pretty tight. Pliers were threatening to chew up the outside of the piston, and one of those hand-held piston removal tools just didn't have the grip required. It was hard-work, but the socket trick was the only way I got them out! Brililant.

[@LiveWire_Guy]

I'd just finished my fronts on a zrx1100 which were really stuck. Then your video popped up and I saw your technique for removing the pistons. That's absolutely brilliant. Wow I haven't seen any technique this cool in wrenching bikes since 1978. lol.

[@Moonfleet41]

Most wecome mate. Glad I could help, really appreciate the kind feedback.

[@CtiStu]

Hi Del, you probably don't remember but about 3 years ago I messaged you saying how I enjoyed your video's and it helped me through my cancer treatment even gave me the mojo to get my RGV sorted, you and penny kindly sent me a cap and some stickers, well the treatment seems to have worked and I'm still here watching every video!! just wanted to say I'd decided to have my 6 pots on my bandit 12 rebuilt, and the next day this video pops up, so I gave it ago myself and have saved myself about £150 😊😊👍 cheers

[@Moonfleet41]

Hi Stuart, Wow, thats such good news buddy, you beat the bad guy for sure.. and so glad you're well again and still faffing about with bikes.. Massive respect for kicking back and getting your mojo back, it's easy to fall into self pity and give up, no doubt you're made of stronger stuff aye. Glad the video saved you the rebuild, nothing better then getting it done yourself mate.. Take care, Ride safe, and enjoy every day Stu... Keep in touch mate, be good to hear from you any time.. D&Pxx

[@PaulR387]

Blimey what a great trick with the Extension and socket with the pots, every video of yours is worth watching Del for these Gems of experience for us that don’t know, top man…

[@Moonfleet41]

Glad you enjoyed it Paul, you're most welcome, am glad you enjoy what we do, and thank you for your support in all ways.

[@KensWorldRestorations]

Dell - I know this video is 5 years old but I have to comment on how much this video has helped me. I'm not a mechanic but very mechanically inclined. I've restored a number of motorcycles and with every one, I learned a bit more and take on progressively difficult jobs. My 1984 Virago caliper rebuild cost me nearly $300 CAD through nothing more than my ignorance and lack of knowledge having a shop do the work (and that was just the front brakes). I came across this video before I tackled my latest restoration, a 1987 FZR1000 Genesis that I plan to take back to factory new. The air compressor and socket tips were absolutely essential since all the pistons were stuck with this one too. I was able to do all the work myself with seal kits being well under $60. Thank you, thank you, thank you.

[@Moonfleet41]

Most welcome sir, im so glad the video was able to help you out, we have a whole library of videos on lots of work like this that can, as you found, literally save you lots of money on not just your projects, but also day to day servicing so you can keep your bike on the road.. if we've managed to save you as much as you say, then dare i say, maybe consider supporting us on Patreon as that's now we fund the garage and video content.. Thank you again for your kind words of support..!

[@bradleythompson7722]

Like the socket trick. I know I will use it someday. Always a Pleasure Take Care.

[@buaan]

Bradley Thompson me too, never seen that before!

[@TheMissendenFlyer]

Very therapeutic as ever Del - enjoyed that (and I too loved the socket trick!)....

[@Moonfleet41]

Hi buddy, good to hear from ya, yeah simple stuff aye... just absolutely love the ol' Granddad hacks, serve you for a lifetime!

[@davidmcmillan8408]

I find it hypnotically fascinating to watch a great mechanic at work. And this guy is a great mechanic. Meticulous work. I once spent a frustrating & increasingly angry hour looking for a 10mm spanner whilst working under an old TVR, a spanner that I knew I'd already used that day. Eventually found it next to the kettle where I'd made a coffee earlier. Since then, I've laid out all tools and parts on an old towel, like a surgeon, exactly as Del does. Takes time but avoids stratospheric blood pressure readings and makes working on my bikes so much easier.

[@Moonfleet41]

Thanks for sharing your story mate, we're glad that a little tip or trick equals lower blood pressure! Ride safe and thanks for your support.

[@arnybarmy]

Friday and Tuesday are my favourite evenings!!

[@petterbw]

8 of 12 pistons where stuck. Your trick worked. But still had to use a lot of force to the them to move. Perfect timing on the video. Thanks!!

[@Moonfleet41]

Glad it worked for you Petter..

[@ChrisSofos]

Oh man, there's always something new to learn! I could never have guessed the trick you did with the socket and the ratchet to remove the pistons! I'm going to use your trick from now on. Thanks for sharing! Keep up the good work! Subscribed just now 😊

[@Moonfleet41]

Glad to help Chris, thank you for your kind feedback, and welcome aboard.

[@danparsonage3884]

I watched this video before I rebuilt my Nissin 4 pot calipers. I was so confident thanks to you Delboy and that I thank you for my friend. 🙏🏼

[@Moonfleet41]

Great to hear, you're welcome!

[@abelbabel8484]

That method of taking the pistons out blew my mind right out the back of my head. That is elegant and ingenious. Now excuse me while I look for my jaw, it must have dropped somewhere around here

[@Moonfleet41]

Ha ha.. Comment of the day buddy... Simple trick aye.. basic stuff for any mechanic..!

[@Pdtuning]

A handy thing I find to use instead of blue roll is cheap large puppy pads. Think the wife picked up a pack of 10 A3 size pads for €5, there clean and absorbent and easy to fold out.

[@AnalogueInTheUK]

Yes please!!!! This project is absolutely fascinating.

[@julianreynolds9076]

I took my Busa out for a ride for the first time in six months yesterday and found that I don't need to pull the brake lever to stop, so your brake refurbishment video will help. Great video and thank you!

[@SamFrisker-rh1ul]

From America: "We can always learn something." My 2000 Hayabusa has stuck front brake calipers. This man is a master mechanic, he knows what he's doing. Now to find out how to bleed these calipers... and, what's the cost of rebuilding versus the cost of buying new ones? Anyhow, this guys is a First Rate Top Mechanic, tripe A+. The little tricks of cracking the bolts on the bike and rotating the pistons. WOW. Really smart. This guy is a pure genius.10-20-23

[@pickwizard-aka-Stevie]

Thanks Delboy, used that trick today on a 25mm piston, worked a treat to twist out a seized piston

[@malcmcleod]

Thanks for the tip to remove the pistons.did my callipers yesterday after watching your video.

[@Moonfleet41]

No problem 👍, glad it could help mate.

[@pat_986]

Thanks so much for the socket trick to get the pistons out - That's saved me a lot of grief!

[@Spad562]

Can't beat the look of a freshly rebuilt caliper. Nice work as usual. 👍

[@midenking9651]

I absolutely adore the process of laying everything out and being methodical.

[@michaelperren5788]

Thanks for the tip using a socket and ratchet to remove the pistons, worked a treat 👍

[@Moonfleet41]

No problem 👍

[@stevesas632]

Brilliant, just got all 6 pistons out of mine using the clever socket idea. Now need to clean, & get new seals etc & hope I can bleed them successfully.

[@meinpostfach9773]

Thx for the detailed elaboration. Finally was able to reassemble. Tomorrow is filling on the list

[@geneva760]

NEATO trick with the socket and ratchet getting the piston out. CHEERS from AUSTRALIA.

[@traieking]

Best video for tokico six pots I can rebuild mine with confidence after watching this, thanks

[@Moonfleet41]

Most welcome Sir, glad it helped!

[@chrisleavey5191]

Just found that I need to strip and rebuild the calipers on my ZX6R so this video is priceless - really clear and logical and it has dispelled most of the fear I had! Thank you

[@Moonfleet41]

Thanks Chris, so glad to hear the videos help you out...have also emailed you privately, you know why, thank you so much for your support... good luck with your projects, hope all goes well, all the best, D&Px

[@gilesbristow123]

Will be using the socket and extension trick in the future, just wish someone had told me about it 30 years plus ago when I think of the number of pistons I've wrestled with over the years. Thank you

[@stuartyoung9078]

That trick with the socket is awesome. Thanks for that !!

[@Moonfleet41]

No problem!

[@somethinburnin]

We discovered my RF Caliper on my Boulevard C90 was weeping last night. Tokico 4 Pot. This rebuild don't look to bad to do, I might go that route!

[@Ct99915]

I removed a few stuck pistons from my triumph today using that socket trick... Absolutely love it mate you legend!!!

[@Moonfleet41]

Most welcome mate, glad it worked for you!

[@SurreyRider]

You made that look super easy, great idea with the 7mm socket I like that!

[@waynepurches2773]

Hi I watched this video yesterday and it worked great the socket technique was brilliant thanks

[@Moonfleet41]

No problem 👍, glad it helped mate.

[@searin]

5yrs late to the video but better late than never will be using this guide tomorrow

[@Edmax52]

thank you so much man! I have to do just this job on my 99 Srad 750, you explained the work to be done really well .. a big thank you from an Italian colleague

[@bluehazeboy]

Top job, liked the little technique with the extension bar & socket,& considering the state of the rear end, the calipers came apart very easily

[@Moonfleet41]

Yeah, i thought so too, i recon they must have been refurbished at some point in the past.. but either way.. they're like new now.. !

[@chriserskine585]

Nice vid Del,some people are put off doing caliper rebuilds but you have shown how straightforward it is, clean clean and more cleaning,always does the trick, hell of a lot cheaper to do the work yerself,👍👍👍🤘

[@marcingmach7915]

That's a neat trick with the socket, i will remember that , thanks

[@BIG-K]

That was a proper job and a pleasure to watch, Del. I especially liked your piston removal tip. Good stuff! 👍

[@Moonfleet41]

Cheers Keith, simple stuff aye.. See you Sunday buddy..

[@T1NY85]

never seen a caliper rebuilt before, not as scary as i imagined, and the trick with the socket was great, great video

[@Moonfleet41]

Simple stuff aye mate.. just House Keeping.!

[@Gus-cg9yp]

Hi Dell, nice and tide job. Good trick that one with the socket, first time I've seen it. Thanks for that. Have a great weekend . Gus

[@Volvi373]

Invaluable video! I wish I saw that 10 yrs ago when I rebuilt my calipers for the very first time in my life with only a manual as point of reference and no way as perfect a job as you did. Im sure you removed the fear of caliper rebuild with that vid. Well done bro, your the master and Im the grasshopper.

[@Moonfleet41]

Hey Volvi, that's very kind of you mate, simple stuff aye, just a case of being meticulous and doing a nice clean install... have a great weekend, ride safe, D&Px

[@chrisrag1346]

Wish i'd known about that trick with the socket when I did mine. 👌

[@ebezgin]

3:34 that's why i have pressed the like button

[@outandaboutinoz]

This was a great resource as I am rebuilding the brakes on my GSX1400, which are the same, cheers.

[@Moonfleet41]

Most welcome mate!

[@smncoffracer4563]

Te felicito, nada más por el truco de extraer los cilindros atorados... no me lo sabía!

[@bubbles1863]

That is a great tip with the socket del u always learn something new with your vids thank you m8

[@postmortemspasm]

Been working on bikes for years and this is the first time ive seen that socket trick. will have to try it next time ive got a seized piston. Great vid

[@xsken2675]

Good demo of how this job should be done. My busa has 110,000 miles on it now so I've had the calipers apart a few times! Always better to do it sooner rather than later. Nice one.

[@Moonfleet41]

110k miles on your Busa... thats impressive Ken... gives me great long term confidence in my engine...!

[@garya3056]

Looking mighty good, Del. Nothing like watching the master at work! 🏍👍🏍

[@Moonfleet41]

Thanks mate, have a good weekend!

[@garya3056]

Moonfleet41 😎

[@donkey1007]

Delboy, you the man. Brilliant tip to get the pots out. Never would've thought of doing that. Educational as always. Learnt so much from your vids. 👍👍👍

[@kunalkhanna985]

Now I know how to pull out that stubborn piston that I am jostling with. Hopefully I can ride again very soon! Always something informative in your videos Del. Great work!

[@malcolmdonohoe9388]

Brilliant instructional vid and the socket and bar tip is genius - will be lodged in my mental database for the future... The issue for me with those Tokicos though isn't so much the difficulty of rebuild and bleeding (if you bleed them as many ways as there are to bleed brakes at once, they do firm up) but the regularity of it. I had a set on my old 7R and had a bloody minded desire to keep it original, rather than just bung the Nissin 4 pots on it, but after my third rebuild in four years, I gave up. They are okay when completely spotless, but you have to keep them *so* clean - they start seizing pistons with any dirt at all. And of course, the cost of the rebuild isn't small when you've got all those pistons and seals to do - it's just the 4 pots end up being a far easier to live with option. In the end, one of the castings on mine actually cracked around the banjo port, so that decided it once and for all. Still - kudos for not taking the easy option and actually trying to disprove the accepted internet chat.

[@Moonfleet41]

Im keeping an open mind on them buddy, of course i have heard all the malignant hate towards them, usually from those with bitter experience of them causing trouble.. but if i start as clean and perfect as this, then maybe they have a chance of proving me wrong.. i keep my caliper clean, even on a Ratbike, so fingers crossed.. i can;t afford to just go out and buy a pair of Bandit Nissins.. they are getting harder to buy cheap now, so this will be the chosen path for now... thanks for watching mate.. take carer. .Del.

[@iamvicfleming8746]

this was awesome. Thank you for sharing.

[@allanbryers4682]

Another intuitive video sir, always a pleasure to watch and lean from you. Great method with the socket and extension to release the pistons. 👍

[@rsbharley4766]

The sun is out 24C . Back from 250km ride and a nice way to end the day with Del's new video. Nice job mate, great trick with the socket. Have to remember that one. Penny and you have a relaxing weekend. Cheers

[@Moonfleet41]

You too buddy.. im envious of your long ride.. but sun's out, and im playin' out tomorrow..!

[@k1ortia]

Surgical precision and attention to detail..👍🏽

[@k1ortia]

New to this, and loving my zx6r g2. Oldschool analogue era. I would like to know how to keep it in good condition, ie, brake and disc change, oil and filters ect. I presume its pretty much the same for all older bikes is it mate? Cheers.

[@ericvannattan9181]

Thanks for the socket trick!! I used it tonight to remove my pistons in the same caliper as yours. Great job on the video!!

[@Moonfleet41]

Most welcome buddy, use whatever works aye?!

[@ericvannattan9181]

@@Moonfleet41 I am rebuilding the same caliper. What torque setting did you use for the body bolts?

[@Moonfleet41]

@@ericvannattan9181 Final full torque value is 21Nm, but don't got straight to it... torque them in three stages, i go 10Nm, 15Nm, and then up to 21Nm... and obviously as they are a long slim casting, it helps to toeque them in sequence.. i go "top most, bottom most, lower middle, upper middle".. that way you won't distort anything mate.!

[@michaelneve3223]

just great watching a job done properly!

[@rebel_ltz]

I used a tool similar to a bearing bridge puller to remove the pistons. Good idea with the socket! Great video!

[@MintyGusto]

You always make this stuff look so damn easy!! Wicked video!

[@paulharast1958]

Awesome video. Thanks for teaching us a new trick.. Penny and You Del Ride Safely and have A Wonderful Weekend.

[@Moonfleet41]

Thanks Paul, you too buddy, ride safe, and enjoy the sunshine! D&Px

[@Dean-qt8jw]

like everyone else, love the trick getting the pots out. Rippa!!!!!!!!

[@raybould]

As others have said in the comments, neat little trick with the socket to get the pots out. I reckon if you did a video about changing a lightbulb I'd learn something new! And - usually I don't take much note of the writing on the board at the end, but today the quote was eerily bang on point. Thank you.

[@Moonfleet41]

Thanks jack, i honestly thought more people would have known the piston grip trick, but there you go, just passing forward an old school technique i learned many years ago. Thanks for watching buddy, and have a good week..

[@thestar111]

Rebuilt my Tokico 6 poters on my 1998 ZX6R today and the calipers look identical. I do like your socket trick to remove the brake pots. Should have looked a this video first as it might have made it a little easier. Mine were in really bad condition, spotless now.

[@liamhoughton]

Excellent video. The socket and ratchet tip is a goodun. Cheers

[@paulbuckberry7683]

Piece of cake Dell!!!!! Liked the trick with the socket and extension bar!!

[@terryblack2219]

Nice little trick with the socket to get the piston out... never seen that one before...

[@raffyc66]

Nice!! The exact ones my 2002 Kawasaki Mean streak rocks. 👍🏽

[@markrobinson6747]

Great video as always so laid back and no dramas...brilliant

[@Moonfleet41]

Sure thing mate, easy task.. Glad you enjoyed it

[@eaglestrikes1]

Fantastic video Del, thank you. Great tip for getting the pistons out. Great work

[@springy-2112]

So much fun watching you rebuild 6 pots..instead of me.. "having done them a good few times" .. they're gonna be great ..as you know, having done them a good few times ..👍🏻.. great viewing Del as always...peace and love brother... day off 200m round trip tomorrow ...at last👍🏻👍🏻 👍🏻👍🏻☮☮❤❤ that's mile not meter of course..😁😁

[@Moonfleet41]

Damn and there was me picturing you, Maude and The Blokes at a Swimming Gala...! Have fun bruv, and enjoy yourself.

[@fader2701]

great way to finish off a friday at work.

[@simplysounds]

good job del, just used the socket method on my 6 pots. they were tough. had to go 3/8 as 1/4 felt it would snap, they were in there

[@Moonfleet41]

Glad it worked for you buddy, as you found, you can adapt the trick as you need to, the principle is the same..

[@sparkeli4513]

That tip with the socket and bar end for piston removal is brilliant! I wish I had known about that trick before I bought a specific piston removal tool which doesn't seem as effective as your socket hack.

[@Moonfleet41]

Glad you liked it buddy, and sorry it wasn't in time to save you buying one.

[@carreteras101]

thanks mate! very helpful video.

[@SalsamichaelA]

Just used the socket trick, works perfect!

[@JosephMask]

Wow bro, que sorprendente tu conocimiento y compartirlo además, eres increíble, saludos hermano, ya pronto veré lo de la placa

[@shaneelson]

You make it look so easy. 👏👏👏👏👏

[@boorhadly]

yeah if it were me, id replace the bolts and pin that were wire weheeled.. id be afraid that there was metal taken off with the grease, reducing their size and holding ability. the organization used in the tear down and reassembly was spot on though. great video

[@Moonfleet41]

Metal isn't taken off by wire wheel cleaning, just unwanted grime and corrosion, it also allows you to inspect the threads to see if the corrosion has eaten it's way in too far, and make the choice to replace if it has ! It would be an interesting experiement to take a dirty bolt and wire wheel it, then closely compare the major and minor diameters againt a new bolt.!! as long as it wasn't badly corroded it should be the same.±

[@davesantathompson2075]

Hey Brother just want to say that by the looks of that bike so far it was a death trap good job you are making it safe for the road. Imagine if someone else had brought that and not checked it over I think you may have saved a life of a biker Much Love And Respect to you and Penny keep up the good work Brother.

[@Moonfleet41]

Hey again Dave, Good to hear from you Brother, Yeah, i recon you're right, it had enough faults and excessive wear to go back for a refund i recon (if you bought it to ride), but it was always to be a donor bike, and has given me a chance to get all the consumable stuff done and renewed, and the guys at the shop are sourcing me a set of forks to replace these.. or they'll replace the chrome sections and rebuild them all for me.. so they're stepping up and doing the right thing aye... Been out on the Dyna all day, got some serious miles under the frame, and happy with how she's all settling down now... Ride safe and keep yer boots in the breeze Brother.. MLL&R, Del.& Pennyx

[@davesantathompson2075]

@@Moonfleet41 Hi Brother Glad you got out on the Harley Ride safe MLH&R

[@cptfrankflyboy]

Hi Delboy Whats the torque setting on the caliper body bolts (x4) ? And the 2 caliper mounting bolts? What lube do you put on the pistons when reassembling? I'm at the reassembly point just waiting for the kit to arrive. Thanks Frank Flyboy

[@markbaines7626]

After a stressful week this has proved a great tonic! Keep at it!

[@whoamiuk1]

great vid, i wish I had known about getting the piston out 3 weeks ago, oh well I know now lol

[@TheJmebe]

They look exactly the same as the calipers on my Zx7r. Have been thinking that they could do with a rebuild... Another of your videos added to favourites!

[@ryan88682]

Deadly video quick tip try putting your brake fluid in an oil can and put it up through the bleed screw.

[@MrSmith-hd8od]

Another smashing vid! I as well, sure wish I would have known about the caliper piston socket trick back in 1988, fighting with my RD350LC seized brake calipers from hell, lol!

[@bigogger50]

Top tip with the socket and good to see the gloves on. I had a busa when they first came out awsome bike apart from the clutch that was like an on off switch maybe it was just mine

[@Moonfleet41]

Hi buddy, No, it wasn't just yours, they have a very dodgy "step' mechanism in the clutch setup.. and ill be replacing it with a modification that eliminates it and makes it behave more like a regular clutch..

[@Volvi373]

@@Moonfleet41 Very interesting, look forward to that mod on the clutch. Very hard launching the busa with that 'step' clutch. Stalling at the lights makes one look like a right dill (as I often did).

[@ccaalluuss]

just in time...I tried to pull 4 of 8 pistons out of my calipers risking to scratch them just yesterday, so damn stuck and inside. I perhaps damaged one but on the very top, should be fine, never reaching the seal height. I will try today again with the wrench tip.tumbs up!

[@cyberjack]

Thank you for "rotating piston" tip ..for years I've been grabbing it with taped up pincers .. obviously not a good idea lol ..

[@Moonfleet41]

Has ha.. erm, no.. not clever.. and easy to distort the piston so it jams up later.. Glad it could help you mate.. Del..

[@TriDon-gw4wb]

Another great job Del . I really do like watching your work.

[@a66435]

Great video, made me confident enough to tackle my own caliper rebuild. Anyone ever suffered with weeping around the bleed nipple thread after a rebuild?

[@mikedobkin7548]

I find that a couple of turns of PTFE tape around the threads prevents any leakage - essential to make bleeding a breeze

[@ethanmacheras5967]

Brand new callipers pretty much! 👍

[@moose64]

Not sure why people say these are bad calipers to work on. Done mine on a ZRX and was hesitant as I heard they were brutal to work on. First calipers I've ever done and they were easy peasy. My bench looked like yours with all the blue paper workshop towels. LOL

[@geoffozevans4500]

Nice tidy overhaul, nifty little trick to get that piston.out, all the best to you both x 👍👍😎

[@Moonfleet41]

Cheers Geoff, glad you enjoyed... PP got her card, hasn't opened yet, will tomorrow, she says thanks for remembering her! Have a great weekend buddy, ride safe!

[@geoffozevans4500]

@@Moonfleet41 no worries, you & P have a great weekend

[@ickleshouse]

great video again. I have issue with my gpz 1100 calipers. Its on a project older z1100 ,have got the r clips out but the pin is stuck solid.Once they are apart I will be using the trick to move pistons... another old school fix.

[@waffoo999]

Another great video with some great tips. I’m late to this one tonight because I’ve been doing a radiator swap on my Fazer - gone well so far, coolant in and leak checks tomorrow.

[@Moonfleet41]

Good luck with it Craig, Hope it turns out leak free and perfect... have a good weekend mate. Del

[@perfectox]

That socket trick just saved me a lot of pain! wow! thank you so much for that! ...shame I tried it only AFTER I scratched one of the pistons with pliers :/

[@Moonfleet41]

You're welcome, at least you know now, and can pass it forward in the future.

[@perfectox]

@@Moonfleet41 definitely! Thanks man :) do you think I can get away with replacing only that one scratched piston? or is there a high chance that the "old ones" got thinner over time and I would create problems and uneven pressure on pads with with it? It is on the cbr600f4i which doesnt have floating calipers, so similiar to your video, I have 2 pistons from each side of the brake disc. The 7 pistons I did not scratch look brand new.. thanks for advice. And keep up the great work you do here for us! :)

[@Moonfleet41]

@@perfectox I've scratched a piston in the past and with a bit of effort you can polish it out if it's not too deep, started out with 1200grit paper to lose the sharp bits, then gave it some 'welly' on the buffer, got it back to a irror finish, fitted it and it works just fine... new seals would be the best idea as they will take up any wear in the piston and give you half a chance of getting away with replacing them, as long as they are clean and not damaged, they'll work just fine.

[@josebaez5758]

Nice video ,you are the best