brake piston removal

David kerr ddjj660 at
Mon Nov 5 16:24:54 PST 2007

thanks for the advice. I'll try that tonight.

so you'd be the half glass empty guy? Seriously though. Are you talking about corrosion in the chambers themselves or elsewhere or both? If so, i assume the evidence will be rust or something else obvious.


----- Original Message ----
From: Ernest Montague <afm199 at>
To: Suzuki SV650 Mailing List <sv650 at>
Sent: Monday, November 5, 2007 5:39:35 AM
Subject: Re: brake piston removal

at this point I would look for a system on ebay, yurs  is probably 
totally corroded.

On Nov 4, 2007, at 11:23 PM, Donlon McGovern wrote:

> It sounds like you have accumulated water in your brake fluid, hence 
> the cloudy, creamy texture. Good thing you are disassembling them. If
> I were doing it I would bleed all the old fluid out of the system
> clean fluid and get all the creamy stuff out. Then, once you have 
> removed the caliper assemblies you should be able to just squeeze the
> brake lever and push the pucks out enough to pull them out by hand. 
> You will probably have to replace the rubber seals and use a fine 
> abrasive emery paper to gently scrub the cylinders if they are rusty.
> But, if they are just cruddy, a good brake cleaning fluid should
> the crud out. With the seals back in place you should be able to push
> the pucks back in but you might need a stiff section of thin board to
> get them flat with the surface of the caliper assembly. Mount them 
> back, squeeze the brake lever to reseat the pads and then bleed again
> until you get all the air bubbles out. There may be other suggestions
> from Zoran or Jim Stewart or any other listers that have done this
> more often than me. I'd say you biggest problem is not bleeding your 
> brakes often enough to purge water out of the system. Remember, brake
> fluid is hydroscopic, it absorbs dihydrogen oxide (fancy name for 
> water).
> dm
> ----- Original Message ----- From: "David kerr"
> So, this is the first time I've disassembled the brakes on my '99 
> SV650x. So far I have discovered that the brake  "fluid" was white
> the cinsistancy of room temperature sour cream. What causes this?
> I've also discovered that one or two of the seals are pushed out and 
> showing next to the pistons.
> 2nd Question: How in the world do you remove the brake pistons
> the use of compressed air from the back as the service manual 
> suggests. I obviously don't want to scratch, scar or squeeze the 
> pistons, so what's the trick?
> Lastly, any tips on cleaning and replacing the same pistons?
> Thanks,
> David

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