Caliper repair advice

apostrophe · Mar 24, 2012

Can anyone help please?

I have only come across one issue while servicing my Mille this winter. The left hand caliper is leaking brake fluid onto the disk. It is the standard 2003 4 pot non-radial type. Looks like it's a failed seal, I'll investigate further tomorrow. I can't see that it's leaking from the line/banjo bolt.

I understand that there is a KTM seal kit (Part number 61013019100). Does anyone know if that is the right part. Where can I get one from and how much? Is it easy to fit the seals?

Has anyone paid to have one of these calipers serviced. How much was it and who did it?

Cheers

Rob

2TROKE · Mar 24, 2012

apostrophe said:
Can anyone help please?

I have only come across one issue while servicing my Mille this winter. The left hand caliper is leaking brake fluid onto the disk. It is the standard 2003 4 pot non-radial type. Looks like it's a failed seal, I'll investigate further tomorrow. I can't see that it's leaking from the line/banjo bolt.

I understand that there is a KTM seal kit (Part number 61013019100). Does anyone know if that is the right part. Where can I get one from and how much? Is it easy to fit the seals?

Has anyone paid to have one of these calipers serviced. How much was it and who did it?

Cheers

Rob

A caliper stripdown is quite easy really..... firstly remove caliper as if replacing the pads..........then release fluid into a container......remove the caliper/s then it.... will make it a lot easier to work on.....get it on the bench....1st ....1st take off the dust seals over the top of the caliper pistons you could use compressed air to blow the pistons out but I would just gently easy them out with a blunt tool just make sure you do not indet/or mark the caliper pistons whatsover!!! Or they won't ever be the same again!! If you've got new 1's fine but also watch the body of the caliper!! As you ease the pistons out you willl see the seals on them thay are just basically like big o rings...............if you got the savvy you should be able to do both sides within 2 hours!!

apostrophe · Mar 26, 2012

Thanks 5troke, it is straightforward, but I think your calipers are different. Mine are not the type where the dust seal is visible and covers the area where the piston exits the bore. I've seen those before on other vehicles. The dust and pressure seals on this model are both like o-rings. They are both located in the bore and are completely concealed by the piston until the piston is fully removed.

Rob

2TROKE · Mar 26, 2012

Still easy to do m8 same as realease the fluid get it on a work surface ease the piston out how u see best then get them seals oot and replaced!!! just remember to put a bit of fluid on the new seals when repalcing the piston.....oh and rubbing it with the finest emery on any corrosion spots u find using water!!!

apostrophe · Mar 27, 2012

2TROKE said:
Still easy to do m8 same as realease the fluid get it on a work surface ease the piston out how u see best then get them seals oot and replaced!!! just remember to put a bit of fluid on the new seals when repalcing the piston.....oh and rubbing it with the finest emery on any corrosion spots u find using water!!!

The only challenge so far was finding a torx bit the right size for the caliper half bolts. The pistons are all out and old seals removed. I made a piston removal tool with 2 pieces of wood and a cable tie. There was no corrosion on any of the caliper or piston parts and they are all cleaned with brake cleaner and awaiting arrival of new seals and caliper half bolts etc.

Rob

BB1000 · Mar 27, 2012

was the part number correct ...or are you waiting to find out

apostrophe · Mar 27, 2012

BB1000 said:
was the part number correct ...or are you waiting to find out

I'm told it is correct but I have not ordered them yet. They are available here at £16.38 per kit + £3.50 p&p (just over £36 delivered) http://www.speedaway.co.uk/part/1042...4x/per_page/12

I may however get the seals from this guy: http://www.powerhouseautomotive.co.uk/content/brake-caliper-service-sheffield-yorkshire.html and also get new banjo bolts and washers, caliper half seals, caliper half bolts, bleed nipples , dust caps and do the job 'properly'. It's about £61 delivered.

Rob

2TROKE · Mar 27, 2012

apostrophe said:
I'm told it is correct but I have not ordered them yet. They are available here at £16.38 per kit + £3.50 p&p (just over £36 delivered) http://www.speedaway.co.uk/part/1042...4x/per_page/12

I may however get the seals from this guy: http://www.powerhouseautomotive.co.uk/content/brake-caliper-service-sheffield-yorkshire.html and also get new banjo bolts and washers, caliper half seals, caliper half bolts, bleed nipples , dust caps and do the job 'properly'. It's about £61 delivered.

Rob

Glad to see you gonna tackle it bud no better way than doin stuff yourself at least you'll know if what to do if the occasion presents itself again :thumbup

apostrophe · Mar 27, 2012

2TROKE said:
Glad to see you gonna tackle it bud no better way than doin stuff yourself at least you'll know if what to do if the occasion presents itself again :thumbup

Yeah, I've ordered the parts from Powerhouse today. I usually end up doing bike stuff myself (unlike car fixing stuff). The only thing that might stop me is if I needed some kind of specialist tool etc.

Hope to have her ready to roll by 1st of April. I'll let you know how I get on.

Rob

apostrophe · Apr 6, 2012

Just a quick update on Powerhouse Automotive. They seem to specialise in Nissin and Tokico but they knew exactly what I needed when I talked to them about my Brembos. They offered advice over the phone, they supplied all the right parts at a reasonable price and delivered next day.

I was very impressed with them.

Rob

2TROKE · Apr 6, 2012

So when u planning to get the calipers back together dude!!??

apostrophe · Apr 6, 2012

2TROKE said:
So when u planning to get the calipers back together dude!!??

Sorry I forgot to say that work is all done. Calipers all rebuilt with new seals, all new stainless fittings and new sbs pads (from Tash).

Bike is all back together but weather here has been ****. Several inches of snow earlier this week and still some of that around just a few miles from here. Lots of new salt and grit on the roads too. I will insure and tax tomorrow and hope to go out before the end of the weekend.

Rob

2TROKE · Apr 6, 2012

Good work chief!!
I'm in the same boat although weather down here ok just made a rather large **** in choice of kit I bought...........so I got no indicators LOL!!!...

apostrophe · Apr 6, 2012

2TROKE said:
Good work chief!!
I'm in the same boat although weather down here ok just made a rather large **** in choice of kit I bought...........so I got no indicators LOL!!!...

Yes, I saw your indicator post. I hope to start using mine from Tuesday for the daily commute but only if I get a run in over the weekend to make sure everything is happy.

Rob

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