Tokico 6 piston Caliper Rebuild | Suzuki GSX R 750 SRAD

In today's video I rebuild the front calipers off my 1996 Suzuki GSX-R 750 SRAD. This includes breaking the 6 piston Tokico calipers apart, removing pistons and seals, cleaning them and putting it all back together. I also have a rebuild of the rear 2 piston caliper video on the way!
If you're interested in the GSXR then have a look at my play list for the bike which has all work I've carried out on it to date!
If you enjoyed the video then please leave a comment, a like and subscribe to the channel if you'd like to see more :)
Thanks for watching!!
About me!
My Etsy Shop: www.etsy.com/i...
My Patreon: / thegorillabiker
PayPal: [e-mail]
Instagram: / thegorillabiker
Facebook: / thegorillabiker
Twitter: / bikergorilla
Bikes: Honda CBF1000 2011
Honda Super Magna Vf750c 1987
Suzuki GSX-R 750 SRAD 1996
Honda CB500S 2001
Gear: RST textile jacket, pants & boots
Hood Motorcycle Jeans
HJC FG-ST Helmet
Richa Gloves
Electronics: Cardo Packtalk Bold
Gopro Hero 7 Black
Rollei 625
Nikon D3500
Mental State: I don't own near enough bikes.
#Caliperrebuild #Tokico #GSXR750

[@TheGorillaBiker]

The rear caliper version is coming soon :) Hope you enjoy the video! :)

[@joshhoefelmann4717]

You are the man. I found you when I bought A 1984 magna 750 for 250 bucks last year. All of your content that is you learning / teaching is great. so stoked you make content

[@TheGorillaBiker]

Haha thanks! Glad you enjoy it! Hopefully more people will think the same at some point :)

[@ShannonHartnett-117]

A good way to clean the pistons and housings is to use 0000grade steel wool also good on surface rustbon chrome.

[@stephencartwright5046]

Another good one. Everything underlines the use the bike all the time, and change all the fluids regularly. Love the stainless steel.....bling at its best!

[@TheGorillaBiker]

Thanks :) Absolutely! Literally nothing wrong with this bike but it was left sit so long, and you can see the damage that did all by itself. It also shows if all the fluids had simply been drained it would have been 90% easier to sort.

[@richardbranton190]

Thanks for the video I'm getting ready to tackle this exact rotors tomorrow. My bike has been sitting for 15 years and everything is stuck even the master cylinders👍

[@TheGorillaBiker]

You are more than welcome, I'm always glad when they are useful to someone :) Ah lovely, I do have a video rebuilding a master cylinder somewhere I'll see can I find it. Wait, turns out I haven't recorded one yet :D

[@garrymuir1442]

Nice work. I bit the bullet and bought a 15L ultrasonic cleaner to do the carbs, and clean the front calipers before rebuilding them. Just waiting for to arrive, hopefully before Christmas.

[@TheGorillaBiker]

Ah very nice! 15L will be the absolute job for that stuff :) 9L is grand but the carbs have to be split fully or like dipped 50/50 that way :)

[@Tookarooks]

Well done my friend and hello from Australia..

[@TheGorillaBiker]

Thanks and hello! You have nicer weather than me, I am jealous 😂

[@ChopperFett]

Wow nice work man! Very informative and can apply to many applications.

[@TheGorillaBiker]

Thanks bud :) Yeah honestly every standard caliper is the exact same pretty much, even fancier ones are just harder to bleed due to abs etc.

[@HalfdeadRider]

Hi GB, hope you're well! I just watched this again as I finally got hold of a manky set for my bike to refurbish. Original on the ZX9r too, but people always change them for 4 pots as they are useless at rebuilding and bleeding them lol. It's going to get costly, but initially only cost me £9.50, gonna cost around £250 in total, poss a bit more by the time I'm finished. I'll be buying the same mounting bolts from pro bolt, ordered those other SS bolts from ebay earlier, also ordered new pad retaining springs, surprisingly cheaper from Kawasaki than Wemoto, by a lot. Gonna be a while doing these as need seals, and pistons too which at the cheapest I've found will still cost up to £150, and pads, pad retaining pins and R-Clips. I'll also paint them as I did my 4 pots, purple with gold lettering, fun project but gonna take a while due to costs. This video helped me figure out exactly what bits are missing, and what needs replacing, thanks for that 😎👍

[@TheGorillaBiker]

I'm doing alright man, this whole moving country craic is slow going though :D Haha the amount of people I know who binned a set of these because they couldn't bleed them is mad, great brakes really!! That's still really really cheap all things considered for what will be very well done brakes once you're done with them :) That is surprising, shows why it pays to shop around though and check everything eh!! Yeah pistons are the real killer, very lucky I manage to rescue mine!! Hey worth taking the time and doing them all the same, once they're done they'll be absolutely class, pity money is a thing. Stops us doing all the bikes. Ah well thanks for letting me know and I'm glad to be of some help!! :) Sorry for the delay in responding, country move etc.

[@HalfdeadRider]

@@TheGorillaBiker Yea they'll be great once done 👍 No worries on the late reply we know you're a busy man, good luck with the move, I'll keep an eye out for any updates!

[@Roostabergers]

nice one. Happy New Year man.

[@TheGorillaBiker]

Thanks man, you too :)

[@kevinspalding5470]

Great video mate , I'm doing the front calipers on my 600 bandit at mo so found this very useful. I extract the pistons though by operating the brakes . I crack all the bolts and stuff beforehand ,take the calipers off place them in a pan or vessel that's supported so that all the fluid that comes out is caught , pop the pistons out , let the brakepipes drain then disconnect the calipers and dismantle on the bench . Obviously you have to be careful of the fluid because it is not kind to paintwork and you do not want it on the discs if you can help it . I refill system using back fill method with an adapted squeeze bottle . It works for me .

[@TheGorillaBiker]

Thanks! Glad it was :) What you didn't see is this bike was sitting 13 years before I got at it and those pistons were frozen when j tried exactly that :) Definitely easier ways to do it than this if your system is still working prior to the rebuild :) The backfill thing I really have to try as itd save a hell of a lot of time and fluid I think.

[@kevinspalding5470]

@@TheGorillaBiker I know what you mean about seized pistons I had the same problem and I couldn't get hold of a pair of those piston removal pliers from anywhere !. Tried all sorts to get them out , took calipers to my local garage and they couldn't remove them as compressed air didn't work . Do had to return to hydraulic method!...but used backfill method ,you ought to try it mate it's quite good as you don't get air trapped in the pipes .

[@TheGorillaBiker]

I know the feeling! The only way I could get the rest pistons out was air and it read 11 bar before it gave finally! Ah lovely. I wouldn't like to have to refill everything just to take it apart 😂 Yeah so I've heard! I'll def give it a try :)

[@kevinspalding5470]

@@TheGorillaBiker I had no choice but to refill and then strip them again but I've learnt now and always use same method . Eh regular maintenance pays off!

[@TheGorillaBiker]

Oh god yeah, everything in my collection gets regularly looked after, to avoid situations such as this one 😂

[@kazawhaki60]

Believe it or not I have done this job on the Gtr previously and it was a pain (bear in mind I had to work on the floor of the young lads playroom due to a lack of garage 🙄) and i ended up throwing the calipers in the boot of the car and bringing them to the local petrol station to blow out the pistons using the air compressor there. Some craic on a wet miserable November night.

[@TheGorillaBiker]

Yeah it's not the most fun but it's grand with a garage :) You're more than welcome to visit once we're allowed again and tinker 😁 Yeah I had to blow the rear pistons out at the dads shed as the tool was too small.....wouldn't have been fun in the rain at a petrol station no...

[@patbyrne4656]

G00d man thanks

[@TheGorillaBiker]

Glad you liked the video!

[@jimnotbob]

A handy way of getting badly stuck pistons out is stick a grease nipple on the bleed screw and pump them out with a grease gun. When one is almost out hold it in place with a G clamp and pump out the next one until you have them all almost out.

[@TheGorillaBiker]

Ahhh now I hadn't heard of that one but I have both to hand(well dad does but he won't mind me robbing them) that would have made the rear caliper much easier! Thanks, that's one for the memory bank :)

[@jimnotbob]

@@TheGorillaBiker that's a trade secret, one a lot of lads keep in the tool box 😂👍👍

[@TheGorillaBiker]

Haha I was wondering, I always think to myself the pros haaaave to have an easier way than this 😂

[@jimnotbob]

@@TheGorillaBiker there are various ways of doing it, that's one I found very effective over the years, controlled pressure. Airlines are lethal, I'd never like to see anyone do that. Anyone in the trade long enough knows every day is a school day, we are always learning.

[@TheGorillaBiker]

Yeah compressed air isn't great and it's why I didn't want to resort to that! Great way to look at it, plus learning stuff is just fun anyway :)

[@daithimurphy1832]

Hi GB. I find it better take brake pads out and pump the pistons out before disconnecting the brake lines. Nice job you do e though keep it going 👌can I ask what litre your ultrasonic cleaner is and how much it was. Thanks

[@MonkeyButtRides]

Oh snap, great idea! I have to do my brakes soon (week or 2) will use this tip for sure. Although compressed air at about 120 PSI could be fun😁 .

[@daithimurphy1832]

@@MonkeyButtRides 😄😄don't forget to duck

[@MonkeyButtRides]

@@daithimurphy1832 I think my brakes may be frozen so ducking might be my only option.😂👊.

[@TheGorillaBiker]

I would have done that but sadly sitting as long as they were the brakes were completely frozen so pumping did precisely zero :'( It's a 9 litre tank, made by sealey and cost far too much money, 350ish I think I paid. Also yes, @monkey-butt.....duck a lot :D

[@daithimurphy1832]

@@TheGorillaBiker ok thanks for reply. Not too much money if its doing its job..

[@mrElpacas]

ultrasonic cleaners do amazing jobs on minis, bath in meths and the paint just melts off in a cloud. better to be safe than sorry, replace what you can, those rubber seals do go crap with age too seen some cowboy builds and bodges in my time, your definatly not doing one, your doing a enthusiast job to get the bike back on the road. i had never done a rebuild when i did my first one, i did a cracking job with the limited resources i had at the time, that concourse standard rebuild got me a job that i spent 7 years doing. ive seen worse for sure, they were a bit nasty tho :p

[@TheGorillaBiker]

Haha watching that cloud grow is really cool :) Those rubber seals were solid as a rock I'd say I'd have gotten a few weeks out of them max. Thanks lad, some people just want to hand everything to qualified mechanics, obviously they have already won the lotto, I'm still waiting :P Jesus that's good going I'm fairness! I'm hoping if I build everything up right people might send me carbs and brakes to re do :) They were just crusty as hell 😂

[@mrElpacas]

@@TheGorillaBiker yeah those clouds are like watching evil taint getting banished lol you might of been lucky to get a few weeks out of them... they might not of even lasted that I could understand it if it was something modern jam packed with electronics and such, but its hardly rocket science, a qualified mechanic would probably be doing exactly the same as yourself, looking at guides as the odds are they might not have done one before or atleast done one in a long time due to their being so many manufacturers etc, even specialised mechanics might not of worked on everything in their field. i could name part numbers from memory off with ease, but i would still have to check manuals to refresh myself the right way to do it. i was working at the place already but i was litterally in the lowest job there (general dogsbody sweep), but it was a time of self reflection and easy money tbh, I turned up in the car i had restored and was "borrowing" some works antifreeze and the boss caught me... he said come and see me in the morning, i thought i was going to get the chop, he instead asked all about the car and who did all the work, i did everything to it apart from some welding on the shell, everything else i had done, engine gearbox axle etc. offered me a job in the garage with a huge payrise and better hours and benefits all based on the work i had done. if you offer a good service at the right price, you should be grand as your evidence of the work videos are on here :D

[@TheGorillaBiker]

Yeah once the seals heated they may have just given up, very true! Yeah I mean I have a good confidance in what I do, I wouldn't ride my bikes so much if I didn't and that shouuuuuuld be enough for everyone else. I do appreciate when people point out actual mistakes tho, that's always helpful and always will be :) That's actually a class story :D He'd have been fair harsh to sack you for borrowing antifreeze :P This is true....Gorilla Industries inbound :P

[@TheGorillaBiker]

Grant I'd say mechanics cringe watching my videos :D

[@mrElpacas]

@@badgerman23 to be honest i prefer working on bikes, atlest older ones. ive spannered from a young age though, i worked as a fitter until industrial injury forced me out of that profession, ive rebuilt quite a few vehicles both cars and bikes, including 2 complete down to chasis restorations and rebuilds on a 1980 chevette (back to concourse condition) and a 1975 swb landrover which became heavily modified engine wise, have also done a couple of complete down to frame strip and rebuilds on motorbikes too, my last being a 87 suzuki gs450e, which was good up until the new owner crashed it... i did a sympathetic restoration about 4 years ago now, it was a lwb ex military landrover i imported from the uk, i still have this and ive had it out to a couple of landrover runs and even the millitary show in cork. my grandad was a boiler maker and my dad a marine engineer, they have always said do a job propper dont do a bodge job, i was forever helping out fixing cars, boats etc from a young age. if im not happy with it myself i wouldnt let anyone else be happy with it. to be honest i havent encountered much cowboy mechanical work here, but when i get around to buying a bike again i wont be trusting anything on it till ive stripped it down and inspected everything and sorted out any issues, be that done in my shed or in the kitchen... if the wife lets me get away with that again :D

[@hachewie]

Ahhh man man I hate losing footage.

[@TheGorillaBiker]

Ah it's not so bad I didn't lose any of the important stuff. Still no idea why the camera decided to get upset but it's been rock solid otherwise so I can't complain! :)

[@zainalismat3725]

hi sir...want to ask you about the dustseal and the rubber ring size for this caliper...i just bought a pair...and i want rebuilt it...

[@TheGorillaBiker]

What do you want to ask? :)

[@markpearce5793]

Hi GB, I have to remove the brake pistons on my Thunderace. They are four pot opposed calipers that don't split and I don't have access to compressed air. Haynes manual says to block one side with wood and use brake lever to push the other side out. Then remove seals and replace pistons and use lever to push opposite side out. I can't visualise how that would work without squirting large quantities of brake fluid everywhere. I'd like to use that tool you have. What make is it please and where to get it if you remember. Cheers :)

[@TheGorillaBiker]

Ah lovely, they can be a pain to get apart! It does work fairly well, but yes it can get a little messy, it's not as bad as you think tho you don't lose that much fluid doing it if you get stuck doing it that way! I don't remember but it'll be in my ebay history, I'll try dig it out and send it to you :)

[@markpearce5793]

@@TheGorillaBiker That's very helpful, cheers :)

[@TheGorillaBiker]

www.ebay.ie/itm/Motorcycle-Bike-Brake-Caliper-Piston-Removal-Remover-Pliers-17-5mm-33mm-/123919326395?mkcid=16&mkevt=1&_trksid=p2349624.m46890.l6249&mkrid=710-127635-2958-0

[@kingdavid2018]

My front brake rattles when low speed with no brake applied

[@TheGorillaBiker]

Is there a question in this? Sorry for the slow reply, I was moving country.

[@TYRONE_SHOELACES]

My God Man, you have come through for me yet again. I just should shut up and put my money where my mouth is and send you a couple of dollars for your content. I'm in Halifax, Nova Scotia, Canada. I have a 99' GSXR 750 W that I bought almost brand new and now it has 83,000 kms on it and still going strong. Just today, I took it out for a really high speed run but noticed it's not braking properly. I stopped the bike and notice I had a mushy brake lever, but when I put the wheel up and spun it and then hit the front brake, a noticable " CLUNK" comes from the left caliper and when I let go of the lever, ANOTHER "clunk" .. Jesus, it sounds so wrong, a mechanical clunk as if there's no fluid and something just smashed the pistons against the rotor, I put my hand on the caliper as I did it over and over and you can feel the pistons hitting home hard, dam hard to explain that noise. I haven't taken the caliper off yet, I was trying to buy a new one, or a aftermarket replacement one or even a used one .. NOTHING can be found, so now I'm going to the shop tomorrow and buy a complete rebuild kit, new pads and do the rebuild myself, but I hoped someone online might have a rebuild video of my exact caliper and ONLY YOU have a video...I haven't even seen it yet, once I found you, I wanted to say thank you for uploading this video. One thing I'm going to do tomorrow morning is remove the caliper and inspect the pistons to see if I should spend the extra money and purchase new ones.

[@TheGorillaBiker]

I was going to say check in on a comment here about orientation of seals, but I see you already found it which is good :) I lost access to that email for a long time when I moved so I never got to get back to that fella again. Happy the videos are helpful tho, and I appreciate you letting me know as that's why I made them :) I hope your GSXR is on the road for many years to come!! Also check cmsnl.com for parts!!

[@Exit13Boxing]

What's the name of that tool I have to do exactly this on my zx7r

[@TheGorillaBiker]

I don't know exactly, but caliper piston removal tool should find you loads of them on ebay.

[@Exit13Boxing]

@@TheGorillaBiker yeah thanks I checked them out I had given up trying to get it out and ride with no back caliper and my fronts are now sticking too ....!!!! Life saver this is my first bike and I was sold when it shot flames out the back I never rode before this bike 😆

[@SpiffMcFluff]

-inappropriate giggling- bleed heheheh

[@TheGorillaBiker]

😂😂😂😂😂

[@Jake-pd6ct]

GSXR GSXR GSXR GSXR! THE RETURN OF JAKE! I know it's been tough without me. There was a lot of cans drank during christmas, a lot of food cooked, and a lot of hangover. Impossible to make such quality comments as I do now. BUT I AM BACK AND BETTER THAN EVER Hello mr. intro :) I want to shave your beard to stick it to my face How was your christmas? I think I weigh an extra stone now I ate so much I started this comment the day the video came out hahaahaaha u said nipple!11111!!!!1!!1111!11111 Believe it or not I actually put a caliper from a 97 srad into the skip the other week. Never even thought to ask you if you wanted it Give me names of people chatting shit and I'll turn up to their houses Can't wait for the bike to be done Very nasty K LOVE YOU

[@TheGorillaBiker]

You ruined my Christmas tbh, when I missed out on Jake comments it just wasn't the same yano. :'( The intro was especially for you and all :P Nah that just feel like glue and be unpleasant 😂 I 100% out on a stone in food and drink....soooo...it was good! 😂 I also did lots of work on the gsxr. So even better. That's actually devastating. Go dig it out of the bin I'll take it! Nah they're just silly. In fairness I've had plenty of other mechanics message to say I'm doing a decent job! Bye. I'm going to call you the Grinch now cus you ruined christmas 😭😭

[@Jake-pd6ct]

IM SORRY :( forgve meh pls

[@TheGorillaBiker]

Fine.....you're forgiven

[@Jake-pd6ct]

Thankyou. I hope I didnt miss anything important in the last two videos

[@TheGorillaBiker]

@@Jake-pd6ct Only the secrets about who I am and the gsxr.

[@hachewie]

Nipples are great, blood nipples... I’m not so sure.

[@TheGorillaBiker]

Blood nipples have happened to me many times while running 😂😂😂 They are not good.

[@hachewie]

@@TheGorillaBiker hahahaha. Ouch. Bloody hurts. I’ve had chaffed nips from body boarding plenty of times.

[@TheGorillaBiker]

Yeah it's not great, I never notice when I'm running only the next day 😂