Restoration - TOKICO Caliper - Part 1

[@Prestonesfpv]

I had those calibers on my 07. Zrx1200r and they had a reputation for being not quite so good, i drove that thing for 89.000km and they allways worked perfectly with plenty of power and feel, but i also serviced them twice a year, pumping pistons foreward, cleaning them and lube them, a bit of sercie goes a loooong way for the function of things

[@garyr4818]

Always hurts to see somebody take something apart thats in better nick than your own and hearing them talk about how bad it is 😂

[@richardjones2151]

SUPERB Dirty Garage Vid!...loved this thanks 🙂

[@scottallman9324]

Did a set of these on a 99 zx6r I had a few years ago. Bought a kit from a company called powerhouse that included stainless steel pistons and those calipers were never a problem again. I think you did this the long way lol just split the caliper and pull the pistons out with mole grips and replace with the new ones too much faffing about there they weren't even that stuck and those pistons are better off replaced with the stainless ones the old ones are only good for the bin anyway.

[@dirtygarageguy]

No. You hack.

[@scottallman9324]

@@dirtygarageguy only if you wanted to re use the old pistons otherwise they are rubbish anyway. I put old inner tube rubber over then gripped them and they pulled out no problem. Can't see the point of wasting time on something I will only throw out? If I'm going to rebuild calipers of that age they are getting new stainless pistons the old pistons usually have corrosion and pitting by that point anyway so why bother trying to save them?

[@UnCivilEngineerIRL]

Good thing these calipers didn't have any fins. Or maybe they did and this is attempt no.2

[@killzone32]

pro tip I have a banjo fitting with an inner tube valve welded on so that you can slowly add pressure with a hand pump instead of a compressor

[@RodiGKaya]

Might actually be able to watch this, I can’t do the 6 hour night live broadcasts,

[@ballockybill2277]

My brother has one of those things that surgeons use for keeping your ribs spread while operating, great for pulling out brake pistons. Expensive tool though ,

[@jayflash2035]

Brilliant advert for piston spreaders this

[@wibblywobblyidiotvision]

Them seals are fine. Quick sandblast and pop 'em back in.

[@yakiudon7921]

Thanks for the demystifying video. Do you have a link for those parallel jaw grips? Found Knipex ones, but not sure if they are the same tool, size, etc.

[@dirtygarageguy]

Knipex 8603250

[@billferrie6178]

0:16 My missus was distracted cos your flies undone.😮 You wouldn’t get that sort of thing in Delboys Garage videos. 🤣

[@Itcr0]

Did mine last summer, got the pistons out with air. But if I need to use fluid, is it OK to reuse that fluid? Or just throw it out? Saw that some of the fluid behind one of the pistons looked a bit suss. But the fluid you collected in the cup looked good?

[@dirtygarageguy]

throw it out

[@grahams6690]

thanks for a good tip there,regarding the wood bits

[@JSmith19858]

Just split the caliper and pull the pistons out with an extractor. Takes minutes

[@dirtygarageguy]

No, you hack

[@JSmith19858]

@@dirtygarageguy ah right. Matt doesn't know something so we get the offensive lashing out. An extractor does no damage. I've used them for years rebuilding calipers. Carry on though. Here comes the agressive lashing out

[@dirtygarageguy]

What happens if you wanna reuse the pistons smart arse? What happens if you don't have the tool? I'll await your knowledgeable answer...

[@JSmith19858]

@@dirtygarageguy you just reuse the pistons. What's hard to understand? You buy one.

[@dirtygarageguy]

Answer the other questions... don't dodge them...

[@RS-lm1cz]

thank you Matt for your tutorial and waiting for the next part😊have two questions, 1- i have the same rough texture on my Honda CB250F caliper surfaces. is it a result of its casting process ? sand casting or something ? 2- is there a specific reason for using a rubber seal in between two mating surfaces of the fluid passage ( that small Oring type seal ). just asking since we use copper crush washers to seal the banjo fittings instead of a rubber type seal. keep it up 👍

[@dirtygarageguy]

@RS-lm1cz 1. It depends. It can be just a surface finish for design. 2. The copper washers have to take the twisting action, whilst the o rings are just squashed.

[@RS-lm1cz]

@@dirtygarageguy got it. thank you Matt 😊

[@scooterchannelanddoityoursel]

Nice work Bro❤

[@stevesanelli90]

Are o-rings used between the fluid passage mating faces? Look similar to the Brembo P05's on the Pantah. Cheers

[@RobAKemp]

What media did you use to blast the caliper with?

[@dirtygarageguy]

@@RobAKemp glass

[@deanroberts2021]

Takes me back to when I rebuilt my GSX600 calipers last year, total ball ache. Had rear caliper rebuilt by a local caliper rebuilder & it took him a couple of minutes, he split the calipers first the use an expanding socket type thing in the pistons to twist and pull them out without any real effort. One of those piece of piss jobs if you have the right tools

[@killzone32]

A friend in work had a cracked one of them (I think) on his busa and asked me to weld them back up then got pissed when I said no way 😂

[@jozefsk7456]

if there arent any replacement seals available dor my brake caliper, is there a way to find off the shelf stuff somehow, or if not, how do i choose a new caliper to buy so that it is not only compatible, but up to the task?

[@ballockybill2277]

Measure the old ones if you have them.

[@jediknight1294]

Measure the old ones and from there if you cant get sparws look at calipers from later models of. Your bike

[@imoldgreg13]

I saw bonus content and I was hoping you'd be restoring a knackered old hotel van. 😞

[@andyand100]

The unbleedable ones

[@SixWheelsDown]

are you doing a dave moss impression or are you really out of breath from pushing on a brake lever at 20:30? i can't tell.

[@Chambers36TheEnter]

This is the ideal result. No tools to grip on the pistons and potentially damage them. All removed and re-usable. There's quicker ways but they often result in you taking risks. You save yourself 30 minutes but damage a piston, now you're out of pocket and waiting a week for parts to be delivered or taking more time to ride down to a shop to get the part. Spend a bit more time doing it right or go full Rydel.

[@PaulMappud]

One can "modify" a pair of circlip pliers to grip the inside of the piston if one is so inclined, don't think it happened here cos we didn't see the removal of the deeper buggers, mullered off camera perhaps...

[@forevercomputing]

I have a spares bike, I can be up and running in as long as it takes to get the parts swapped

[@dirtygarageguy]

@PaulMappud lol are you claiming I mulled stuff off camera? Oh no, not other doubters... I'll show you the pistons...

[@PaulMappud]

@@dirtygarageguy Anything's possible, why does the sun come up ? Are stars just pinholes in the curtain of night ? Who knows ? I do know one can claim to be packing the kind of tackle a Grand National winner would be jealous of when one is sporting a micro todge, the proof of ze pudding is in ze eating, if they weren't taken out on camera their provenance can't be guaranteed...

[@sidwainhouse]

I recently rebuilt a set of four pot Tokicos, complete twat to get the pistons out, the seals were in a very similar condition to yours.

[@gafrers]

Great to see something done properly, unlike the usual and endless hacks around

[@H-M-78]

Are they from the SV?

[@paulaven9457]

That's not the same caliper. I saw the jump cut. 😂 nice work Matt. This vid should be called how to rebuild a caliper the correct way !

[@Micky748-r7u]

Is this for project Isaac?

[@prdoohan]

Sand blasting the seal surfaces 🤔 Toolmaker in me goes hmm....

[@dirtygarageguy]

@prdoohan what sealing surface? You mean the seal grooves that the seals don't touch?

[@prdoohan]

​​​@@dirtygarageguythe grooves the square seals sit into? And the faces the o-rings on the split line mate against? I would have taped those off.

[@Matt-we7si]

I split my Triumph TT 600 4 pots , cleaned everything up a treat , all new OEM seals and pistons, but now when I put the halves back together and back on the bike they are being weird, The outer half is moving a lot when you press the brakes, enough so that it will weep fluid out of the caliper split line. Not sure what I can do different ? Does anyone have any ideas. Triumph manual says don't attempt to split them , but why can you buy new OEM split seals. My only thought is to tig weld the caliper halves together so they are rigid.

[@Matt-we7si]

please help im not a hack :)

[@UnCivilEngineerIRL]

That sounds really weird. Not being a prick, but did you make sure the o-rings didn't move when you put the halves together? Is it all torqued to spec ?

[@Matt-we7si]

@@UnCivilEngineerIRL o rings sit lovely in place, I was happy with everything, no torque settings but have done the bolts up to 60nm. Any more they feel like they'll pull threads out. I think the problem is something to do with the alignment of the caliper halves.

[@UnCivilEngineerIRL]

@@Matt-we7si but if the halves weren't aligned then the o-rings wouldn't sit correctly, also the bolts should pretty much align it, no ? Do you have the OEM manual ? I'm gonna check a few that I have here and see what the torque spec is, 60Nm seems high for some reason.

[@UnCivilEngineerIRL]

@@Matt-we7si K1-3 GSXR 600 manual says 21Nm (section 6-58).

[@JayVtec-GAMING]

Why didn't it take you 14 hours to bleed the caliper Matt, You doing it all wrong! 😆

[@dirtygarageguy]

@@JayVtec-GAMING yes!!!!

[@vonsauerkraut]

Why let them get into this state give them a little care now and then and not let them rot away.

[@michanic-c9r]

15mins in and you're doing it all wrong Matt, not wearing gloves so the image is constantly blown out and I cant see a thing. Your compressor obviously isn't powerful enough. You use it but its silent in the background. Obviously if it was a powerful one it would kick in after 6 seconds of use like a certain someones. You're using a vice to hold the calipers?! Come on now, everyone knows you hold them in your hand when working on them. Ideally over a table with a picnic blanket thrown over it. If you must use the vice then you only use it to hold tools. :D

[@Stephane1995]

Del could've done this in a 9:36 video

[@Stephane1995]

First, and my profile picture isn't some bird's behind

[@UnCivilEngineerIRL]

Unfortunately... go change it, cheers.

[@Stephane1995]

@@UnCivilEngineerIRL are you happy now

[@UnCivilEngineerIRL]

@@Stephane1995 very 😏😘😂 Well done 😎

[@jediknight1294]

In before assbot wow

[@UnCivilEngineerIRL]

@@jediknight1294 tbf, she was near my location, so I sent her my bank details so she could get a taxi to come see me.

[@lifesatoy]

obviously not enough red rubber grease was used on the seals, Dell Balls has done a few videos if you need some advice

[@Cub-Guy]

Del could have done a far better job

[@Hverbpro]

I can't see a thing you're doing due to the lack of black gloves - too much white!

[@cliveramsbotty6077]

those 6 pots are a pile of shite. bin them. nissin 4 pots from the bandit is a matched fit.

[@chrisleighton5102]

You can make the 6 pots work just fine. There are good brakes, just a pain in arse bleed properly 😂

[@cliveramsbotty6077]

@@chrisleighton5102 mine leaked brake fluid overnight from between the face plates for no reason

[@IANPARRr]

You got lucky with that pin, and the lack of red rubber grease it just not acceptable. Kent.

[@MsMicheal12345]

god help del_bolocks doing these