SV650 front brake caliper rebuild by a brake engineer. SV650 (1st and 2nd Gen), V-Strom 650/1000

I don't know everything about brakes, but I know some things. This isn't a hard job to get done. If your brakes are acting up, and bleeding isn't the issue, a rebuild and fresh pads should take care of the problem.
This is a 2007 SV650 NON ABS
the part # for the seal rebuild kit for my bike is: 59300-33841
If you're not sure what you have CALL YOUR DEALER. They will be able to order you the correct parts.
Piston Puller (makes life easier):
www.amazon.com/gp/product/B00...
Other bikes with the same calipers (almost identical procedure will apply)
• 1998 Intruder (VL1500) - FRONT CALIPER (MODEL K2/K3/K4)
• 1998 Intruder (VL1500B) - FRONT CALIPER (MODEL K2/K3/K4)
• 1999 Intruder (VL1500) - FRONT CALIPER (MODEL K2/K3/K4)
• 1999 Intruder (VL1500B) - FRONT CALIPER (MODEL K2/K3/K4)
• 2000 Intruder (VL1500) - FRONT CALIPER (MODEL K2/K3/K4)
• 2000 Intruder (VL1500B) - FRONT CALIPER (MODEL K2/K3/K4)
• 2001 Intruder (VL1500) - FRONT CALIPER (MODEL K2/K3/K4)
• 2001 Intruder (VL1500B) - FRONT CALIPER (MODEL K2/K3/K4)
• 2002 Intruder (VL1500) - FRONT CALIPER (MODEL K2/K3/K4)
• 2002 Intruder (VL1500B) - FRONT CALIPER (MODEL K2/K3/K4)
• 2002 V-Strom (DL1000) - FRONT CALIPER
• 2003 SV650 - FRONT CALIPER (SV650K3/SK3/K4/SK4/K5/SK5/K6/SK6/K7/SK7)
• 2003 SV650A - FRONT CALIPER (SV650K3/SK3/K4/SK4/K5/SK5/K6/SK6/K7/SK7)
• 2003 SV650S - FRONT CALIPER (SV650K3/SK3/K4/SK4/K5/SK5/K6/SK6/K7/SK7)
• 2003 Intruder (VL1500) - FRONT CALIPER (MODEL K2/K3/K4)
• 2003 Intruder (VL1500B) - FRONT CALIPER (MODEL K2/K3/K4)
• 2003 V-Strom (DL1000) - FRONT CALIPER
• 2004 GS500F - FRONT CALIPER (NOT FOR U.S. MARKET)
• 2004 SV650 - FRONT CALIPER (SV650K3/SK3/K4/SK4/K5/SK5/K6/SK6/K7/SK7)
• 2004 SV650A - FRONT CALIPER (SV650K3/SK3/K4/SK4/K5/SK5/K6/SK6/K7/SK7)
• 2004 SV650S - FRONT CALIPER (SV650K3/SK3/K4/SK4/K5/SK5/K6/SK6/K7/SK7)
• 2004 Intruder (VL1500) - FRONT CALIPER (MODEL K2/K3/K4)
• 2004 Intruder (VL1500B) - FRONT CALIPER (MODEL K2/K3/K4)
• 2004 Katana (GSX600F) - FRONT CALIPER
• 2004 Katana (GSX750F) - FRONT CALIPER
• 2004 V-Strom (DL1000) - FRONT CALIPER
• 2004 V-Strom (DL650) - FRONT CALIPER
• 2005 GS500F - FRONT CALIPER (NOT FOR U.S. MARKET)
• 2005 SV650 - FRONT CALIPER (SV650K3/SK3/K4/SK4/K5/SK5/K6/SK6/K7/SK7)
• 2005 SV650A - FRONT CALIPER (SV650K3/SK3/K4/SK4/K5/SK5/K6/SK6/K7/SK7)
• 2005 SV650S - FRONT CALIPER (SV650K3/SK3/K4/SK4/K5/SK5/K6/SK6/K7/SK7)
• 2005 Boulevard C90 (VL1500) - FRONT CALIPER
• 2005 Boulevard C90 (VL1500T) - FRONT CALIPER
• 2005 Katana (GSX600F) - FRONT CALIPER
• 2005 Katana (GSX750F) - FRONT CALIPER
• 2005 V-Strom (DL1000) - FRONT CALIPER
• 2005 V-Strom (DL650) - FRONT CALIPER
• 2006 GS500F - FRONT CALIPER (NOT FOR U.S. MARKET)
• 2006 SV650 - FRONT CALIPER (SV650K3/SK3/K4/SK4/K5/SK5/K6/SK6/K7/SK7)
• 2006 SV650A - FRONT CALIPER (SV650K3/SK3/K4/SK4/K5/SK5/K6/SK6/K7/SK7)
• 2006 SV650S - FRONT CALIPER (SV650K3/SK3/K4/SK4/K5/SK5/K6/SK6/K7/SK7)
• 2006 Boulevard C90 (VL1500) - FRONT CALIPER
• 2006 Boulevard C90 (VL1500T) - FRONT CALIPER
• 2006 Katana (GSX600F) - FRONT CALIPER
• 2006 Katana (GSX750F) - FRONT CALIPER
• 2006 V-Strom (DL1000) - FRONT CALIPER
• 2006 V-Strom (DL650) - FRONT CALIPER
• 2007 SV650 - FRONT CALIPER (SV650K3/SK3/K4/SK4/K5/SK5/K6/SK6/K7/SK7)
• 2007 SV650A - FRONT CALIPER (SV650K3/SK3/K4/SK4/K5/SK5/K6/SK6/K7/SK7)
• 2007 SV650S - FRONT CALIPER (SV650K3/SK3/K4/SK4/K5/SK5/K6/SK6/K7/SK7)
• 2007 Boulevard C90 (VL1500) - FRONT CALIPER
• 2007 Boulevard C90 (VL1500T) - FRONT CALIPER
• 2007 V-Strom (DL1000) - FRONT CALIPER
• 2008 SV650 - FRONT CALIPER (SV650K8/SK8/K9/SK9)
• 2008 SV650A - FRONT CALIPER (SV650K8/SK8/K9/SK9)
• 2008 SV650S - FRONT CALIPER (SV650K8/SK8/K9/SK9)
• 2008 SV650SF - FRONT CALIPER (SV650K8/SK8/K9/SK9)
• 2008 Boulevard C90 (VL1500) - FRONT CALIPER
• 2008 Boulevard C90 (VL1500T) - FRONT CALIPER
• 2008 V-Strom (DL1000) - FRONT CALIPER
• 2009 SV650 - FRONT CALIPER (SV650K8/SK8/K9/SK9)
• 2009 SV650A - FRONT CALIPER (SV650K8/SK8/K9/SK9)
• 2009 SV650S - FRONT CALIPER (SV650K8/SK8/K9/SK9)
• 2009 SV650SF - FRONT CALIPER (SV650K8/SK8/K9/SK9)
• 2009 TU250X - FRONT CALIPER
• 2009 Boulevard C90 (VL1500) - FRONT CALIPER
#DAIRYBOYS

[@0x7FFFFFFFFFFF]

Probably the easiest to follow maintenance videos I've seen on here, it's crazy how confusing this stuff is when doing it for the first time, afterwards it becomes a lot easier! Would love to see more SV maintenance guides, maybe like fork oil change or something.

[@svmoto8347]

This saved so much time that others wasted

[@jaimeb82bcn]

Really nice video, clear in explanations and in point of view from the camera is also really good! I have a first gen. SV650S 2002 and was parked outside for 2 years and I am sure I need to rebuild the front and back calipers, thanks for the video I think I will also get one of those piston clamps! Regards from Brooklyn!

[@snorman1911]

Regarding the slide pins, I've seen the grease get crusty and sticky over time so I completely wipe clean both the pin and the cylinder it slides in, including the inside of the boot. Then apply new grease.

[@federicogalli8472]

I did this! Thanks for this video, instruction super clear. I wanted to check the brake calipers status of my SV650N 2007 (16 years old bike) and it turned out that two seals were not so sealing and I found mud inside the calipers. I was lucky enough not to need any clamp.

[@xXDylanXx13]

28 ft lb for mounting , union bolt 16.5ft lb

[@richardohnstad9315]

Very clear, concise, excellent - both the video and the script.

[@favz1]

Fantastic video. Any chance you are in the process of making a rear caliper rebuild video?

[@Philche]

Thank you for putting this video together. I appreciate it. it's really going to help me.

[@maximesauve112]

Thanks mate! Ya saved me a lot of time!

[@tjorger]

Great video! Well done and very helpful!

[@nicholasuselmann2469]

Glad it was helpful!

[@t77snapshot]

Your video was very helpful, thank you ❤

[@RobertWilliams-oy9qk]

Thank you!

[@smitty9999]

I'm not able to remove my mounting bracket with the greased pins from the rest of the caliper. Any suggestions on how to separate the two?

[@locsman]

Are the pistons identical and can go into any of the pots ?

[@matttriestodothings]

Fantastic video man, thank you. I'm actually in the middle of shooting the same video, and I stumbled across this while having some coffee this morning... I'm just going to go ahead and save my time because this is much better! I'm really liking the labels of the torque settings right there for the caliper mounting bolts and front axle. I've got my thermal printer ready to go, so if you see another SV at Blackhawk or Road America with those labels, you'll know who watched your videos. I think I'll grab one of those piston pullers on Amazon as well. One thing I'm curious about is directional fluid seals--they are directional, right? I checked my old ones with my finger prior to removing them, and you can feel that the lip is towards the pressure whereas it's flush on the opposite. However, those seals look damn well square prior to installation. Do you pop them in, check that the seal is in the correct orientation, and then pull them back out and reorient if they did not go in flush? Anyway, I appreciate the time taken to make this video well. I'm currently going through my SV650S that I bought in order to get onto the track, so it's awesome that I just found all your on-track videos as well. It'll give me quite a bit to learn from on lines, shifting points, etc. I think I'll have the brakes finished up today, then the carburetor will be coming off, coolant out and radiator removed, and (crossed-fingers) a valve clearance check. Never done a valve adjustment on shim under bucket, only tappet. We'll see! Alright, i'm blabbing. Thanks for the vids!

[@matttriestodothings]

I'm looking at my fluid seals now, and i've tried seating both ways, and I don't believe they're directional. There's a slope on the pressure side of the cylinder bore that must accomplish the same objective with a square seal.

[@nicholasuselmann2469]

Hey man, this is super late I apologize for that. The Square seals are not directional, but the groove is so they will wear unevenly. See you at the track !

[@matttriestodothings]

@@nicholasuselmann2469 not a problem--and thanks for the clarification. That makes sense because I can definitely feel a little lip after installation, but I felt it regardless of orientation. See you out there!

[@kierancasey2270]

What brand is your piston pullers? Can’t seem to find anything like them in Europe

[@nicholasuselmann2469]

Sorry I'm not sure -- any reverse pliers should do the trick

[@shunjingus]

How do we know it's time to rebuild a caliper? What are the signs?

[@nicholasuselmann2469]

Leaking fluid, brakes sticking on after you have released brake pressure. Also, I'd say if the bike is 10+ years old and has never had this done.

[@junglie]

I use plastic hooked toothpicks to get seals out & clean the grooves they sit in, no chance of sctatching with those.

[@nicholasuselmann2469]

Good idea!

[@junglie]

@@nicholasuselmann2469 yeah, a tip i learned working on HPA airguns, the seal surfaces on those have to be perfect coping with 200 bar pressure, the slightest scratch & the part is toast.

[@TWIRKNOLOVE]

What master are you using for your stock calipers?

[@nicholasuselmann2469]

11/16'' Nissin -- OEM on BMW S1000rr. They are affordable on ebay and much higher quality/better feel than stock.

[@TWIRKNOLOVE]

@@nicholasuselmann2469 Converts to 17.5mm, okay thank you! I just ordered an 18mm Magyar HC1 so hearing you happy with yours makes me feel more confident

[@HootBuilds]

Dang! Is that a race bike! A panty dropper fur sur. Now that everything is cleaned up, you should be able to push it to the limit. ;)

[@nicholasuselmann2469]

Maybe now I can go to the 1 board in T1 like you.

[@richardohnstad9315]

The fact that one piston advances more quickly than the other makes me ask, is that indicative of a problem?

[@nicholasuselmann2469]

nah -- i wouldn't lose sleep over it.

[@farmoboy83]

i use toothpaste with a microfiber cloth to make the marks disapeer on the pistons and make them shine again.

[@TheWanderingGeezer]

No copper grease used, interesting.

[@nicholasuselmann2469]

Anti Seize? Where would you expect it used?

[@flutalors11]

@@nicholasuselmann2469 One of my pad pins totally stuck. killed its nut-head by trying hard with socket, no pliers strong enough etc... Had to drill a hole through the pin and turn/wiggle back and forth a metal stem trough it, for a certain time... used liquid wrench on the 2 areas where it was stuck. I greased it like the rest of the caliper parts, but that was not enough. Could anti-seized have help prevent this? Getting lazy on the maintenance doesn't... Did not do it for at least 8 years of daily rain-0r-shine riding...