Front brake corrosion

[peelbrow]

When I wheeled my bike it gave out a high squeak twice per revolution of the wheels - which I ignored and went to Portugal and back before now getting around to worry about it and seek out the cause. Before this I decided to check the tyre pressures and found that I had to jack up the bike in order to get the front tyre valve in a suitable position. The front wheel was very reluctant to turn and I suspected bearing failure. Not so -the squeak eminated from the front left-hand brake. I removed the front wheel and discovered the brake pistons were rusty thus not able to return as they should.
Here are a couple of pics showing the offending rusty pads and the (unlubricated) pin that holds them in place at one end. I haven't looked at the other side as yet, nor the rear caliper. The bike has done only about 7000+ miles and none in a monsoon. All comments appreciated. Kenp

[ErikDK]

You live in UK, a corrosion prone climate.

The (hard) core posters live in places like Arizona or Texas, where paint is only required for cosmetic reasons.

The safe route for Burgman survival in UK or Scandinavia is to be suspicious about every component and assume Suzuki only designed it for indoor use.

My steel tube TV table is better suited for outdoor use than the Burgman's wheels and frame.

[LeDude]

it can happen depending on where you live and what the put on the roads during those cold Winter months...

I would just strip that caliper down and use an ultrasonic cleaner machine to bring it back to life, it will look as good as new.

-- HF Ultrasonic

I would make it a habit of cleaning the calipers after each harsh Winter, especially if you are a daily commuter.

[herbeckg]

You can replace those pistons with plastic ones. No more rust.

[peelbrow]

You can replace those pistons with plastic ones. No more rust.

Really? I've never heard of this - Where, who, what, when???? Kenp

[NormanB]

Ken
They are much more grotty than I have experienced in 8 years of Burger ownership.
Have suffered from the UK corrosive environment of course but have never seen brake pistons like that.

[InfernoST]

I ride my 400 through all kinds of weather (Except snow) and found the pistons in my calipers to be in fine shape with no rust when I went to change the pads.

Those pistons are in pretty bad shape. I don't know about using plastic replacements (never heard of this), I would think that they wouldn't be able to withstand the heat generated when braking or the pressure being applied to them.

They sell a seal/piston replacement kit for about 11 bucks a side, Here is a link.

http://www.boulevardsuzuki.com/fiche_se ... &fveh=2071

[peelbrow]

Ken
They are much more grotty than I have experienced in 8 years of Burger ownership.
Have suffered from the UK corrosive environment of course but have never seen brake pistons like that.

My bike is an import so who knows where it's been? Luckily the rusty bits are in mid-air and more importantly they are on the non-seal side and as such should clean up okay with no effect on performance. Ah well, here goes - I'll report back. Kenp

[InfernoST]

IMHO, I would replace them, they are just going to rust again and you'll be back in the same boat in short order.

[peelbrow]

IMHO, I would replace them, they are just going to rust again and you'll be back in the same boat in short order.

They won't rust again when I've finished with them! Kenp

[InfernoST]

IMHO, I would replace them, they are just going to rust again and you'll be back in the same boat in short order.

They won't rust again when I've finished with them! Kenp

Cool, if you can post some pics when you get them cleaned up that would be great.

[ErikDK]

There's a guy in Germany who makes all sorts of caliper pistons from stainless steel. I stumbled upon it on the [url]nakedgoldwings.com[/url] website.

http://ngwclub.com/forum/viewtopic.php? ... ss+pistons

I bought genuine new Brembo pistons for my Guzzi, and they were of very light weight material, that didn't sound metallic. Could have been some sort of fiber reinforced plastics.

[peelbrow]

I took both front calipers off and cleaned the pistons up on the bench with fine emery. The near-side (LHD over here) was the worst - initially the two pistons on this were very loath to move but I got them to turn and free up eventually. (I think that most of the braking was being done by only the right-hand caliper). I forgot to take any pics (sorry) and I have now re-assembled them and put them back on the bike. I used proper Brake Grease on all pistons and on sliding pins, springs, and on the back of the pads. I will put the front wheel back in and bleed the brakes tomorrow. Kenp

[ErikDK]

Here's the link for the German guy: http://www.proebstl.net/pistons.html

Could you (Peelbrow) or somebody else measure the pistons to see if any of the 11 types he lists will fit?

Example:

Type1 (Honda-#45107-371-006, outer diameter 38.10mm[=1.5inch or 1 1/2"], height 41.3mm[=1.625inch or 1 5/8"])

[peelbrow]

Here's the link for the German guy: http://www.proebstl.net/pistons.html

Could you (Peelbrow) or somebody else measure the pistons to see if any of the 11 types he lists will fit?

Example:

Type1 (Honda-#45107-371-006, outer diameter 38.10mm[=1.5inch or 1 1/2"], height 41.3mm[=1.625inch or 1 5/8"])

I did a rough vernier measurement whilst the pistons were in situ and got 25mm diameter. I don't know the length because I didn't remove them. Kenp

[ErikDK]

http://www.ebay.de/itm/Bremszangen-REP-Satz-vorn-Suzuki-650-ABS-Burgman-/250821961003?pt=Motorrad_Kraftradteile&hash=item3a6627652b

Piston repair kit for both front calipers (minus the pistons themselves) €55 + shipping

Roughly 25mm you say?

Type7 (Honda-#45107-MN5-006, outer diameter 25.35mm[=1 inch], height 31mm[=1.25inch or 1 1/4"])

That's 4*€25 + €55 + shipping for a complete front caliper(s) overhaul.

Sure beats buying new calipers:

viewtopic.php?f=4&t=53889&hilit=+caliper#p497856

Part no. 59100-21E60-999 2007 Suzuki AN650,A FRONT CALIPER CALIPER ASSY, FRONT RH

Is An650 specific.

Source: http://www.ronayers.com/WhereUsed/N/9935

So is the left hand caliper 59300-21E60-999

Ronayers list them both at $178.66 MSRP: $225.62 (USD + shipping)

In Europe we have to pay 314 Euros or 448 USD, but we don't have that many potholes either.

UK buyers face a price of 344 Pounds or 563 USD, but that includes shipping.

For the difference you could probably fly from UK to US and back.

[ErikDK]

Ronayers.com list a piston set 59300-21810 @ $33 MSPR $38
The fiche clearly shows that the piston set includes both pistons and all 4 seals.

http://www.ronayers.com/ProductDetails/N/687/SKU/794073

List price in Germany €58 = $77

[peelbrow]

You live in UK, a corrosion prone climate. The (hard) core posters live in places like Arizona or Texas, where paint is only required for cosmetic reasons. The safe route for Burgman survival in UK or Scandinavia is to be suspicious about every component and assume Suzuki only designed it for indoor use. My steel tube TV table is better suited for outdoor use than the Burgman's wheels and frame.

My late Nisson Micra lived outside for 12 years without the brake pistons corroding. You NEVER get what you pay for. Kenp