Kawasaki ZX6R J2 Tokico front brake caliper rebuild DIY

My 2001 Kawasaki ZX6R front brakes are binding. The bike is fitted with Tokico 6 pot calipers. Since I got the bike in 2007 I have never stripped the calipers down so this job is well overdue. This will be the first time I have ever attempted a caliper rebuild so took guidance from the service manual and other KZbin bike channels.
J1 / J2
This is my first KZbin video. Welcome to my channel.
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[@mauraudersaif]

Very helpful mate!!! nice one and thanks.

[@hounddf2]

Thanks so much for doing this video. I also have a zx6r-j and the front brakes have seized so I plan to strip them down and replace the pads

[@bikenut]

It’s pretty straightforward actually. I’d recommend unmounting the calliper and trying to use the hydraulic action of the brakes to try to free the pistons as much as possible before you start to strip them down.

[@hounddf2]

@@bikenut thanks for the tip! Did you find out what the issue was that caused the leak? Do you know if it was something you did or just a rubbish seal?

[@bikenut]

I can only assume a bad seals. One was visibly dodgy. The set I purchased second time was from a different supplier too. I also put more effort into cleaning the deposits out of the grooves on my second attempt.

[@PHILIPWATSON82]

You can use heat temperature paint for your calipers that's what I did now they look mint 👍🏼

[@bikenut]

That is exactly what they need - can you get that in the factory colour too? Which one did you use?

[@nicklee9590]

Just done mine look mint, I used deco colour satin gold spray paint, 9.99 and there's enough to do fronts and rears.

[@bikenut]

@@nicklee9590 thanks - looks like Amazon sell that so I’ll get a can. Cheers!

[@SmellyEllie2]

Hi, did you have any trouble bleeding the brakes ? As I know it can be a total pain to bleed then 6 pots...I'm having that problem with my ones

[@bikenut]

Hi, bizarrely not. First time doing it but no issues for me, but it did take a while. I would do the following - make sure each piston is pushed fully in until the back of the piston is in contact with the caliper (ie least amount of space for air to be trapped). Disconnect line from calliper and get fluid flowing, reconnect to calliper with the bleed nipple open and just leave until fluid starts flowing. Close bleed nipple and then start to bleed as normal with a clear pipe. Make sure your fluid level never drops too low so air is allowed back into the system.

[@SmellyEllie2]

@@bikenut I will give that a go...cheers 👍

[@bikenut]

@@SmellyEllie2 good luck, I’ve heard these callipers can be tricky but you will get there. Just make sure also that when bleeding through the clear pipe that you shut off the bleed nipple just as the bubbles stop flowing on each press of the brake lever. If not they can quickly zip back in.

[@ShannonHartnett-117]

You can also use 0000 grade superfine steel wool to clean-up the pistons works a treat on surface rust on chrome also.

[@The_dirty_650]

Good job and nice video but please trim your nails good sir, every time they scratched anything I could feel shivers down my spine

[@bikenut]

Haha, I know I know lol. I have noticed that myself when editing.