Motorcycle Repair: Bake Break, caliper pistons, piston seals


Question
HI I am Karla, with a 2002 750 suzuki, I one day was riding and my bake break went out completely, I filled the front and bake break with DOT 4 break fluid and nothing, tried riding and pumping and the pads are fine........? What you think? Thanks .........my last resort is a Dealer ......

Answer
Karla, the specific model would have been helpful.. GSXR or cruiser or ???   

The back brake system is just a little imitation of the front one, but the parts are smaller, especially the brake reservoir. If you let the fluid get down below the master cylinder's piston ports, which are supposed to be submerged in brake fluid all the time, air will be introduced into the fluid system.. not a good thing. Complete bleeding of the line to the rear caliper is necessary to purge the air out of the system..... Assuming that the rear brake master cylinder has functioning piston seals inside. If the seals are worn or some dirt or water has gotten into the system, the seals can fail to pressurize the fluid to activate the caliper pistons which push on the brake pads. If the rear master cylinder is not scored or corroded inside the cylinder bore, a repair kit can be installed.

When adding fluids, always fill to the FILL line and not all the way to the top. Have the fluid changed about every 2 years or when the brakes need replacing.

Caliper seals can become enlarged by moisture entering the brake fluid (brake fluid attracts water). Then the water goes to the bottom of the system, which is usually the calipers and the seals which fit into the caliper body.
Corrosion builds up between the seal and the caliper body, causing the seals to swell up, gripping the pistons and causing either lack of motion to apply or doesn't allow the pistons to retract, which causes overheated pads and fluid.... and a locked up wheel in extreme cases.
Depending on the number of miles on the machine, where it has been stored/parked, the entire system could need a flush and overhaul of caliper and master cylinder or maybe less.
Have a knowledgeable mechanic inspect the bike and try to flush/bleed the brake line.  Air in motorcycle brakes is notoriously hard to remove, often requiring a vacuum pump system to remove the air bubbles. Many riders seldom use the rear brakes, but they do come in handy for holding the bike on a hill or other circumstances, so get yours inspected and fixed pronto! Check for reputable motorcycle repair shops who can do the work, rather than feeling like you have to take it to a dealership. Depends on where you live and who is working on bikes in your area. Get referrals or references before you choose a repair station. Shops that sponsor racers are often a good bet, but check them out, first!

Bill Silver


Bill Silver