Brake Calipers

[pedrosgoro]

Hello everyone

I've got a DL650 K7 with ABS which has had a bleed nipple snap off one on of the calipers.

I've been hunting around for a new caliper and there are few and far between available. Is anyone aware of any other bikes (for example SV650) that use the same calipers with ABS?

Thanks

[Juvecu]

Could you show us some pictures of the damage? I'm curious to see what it looks like. Why can't you get it out? Also, which side's caliper do you need?

[pedrosgoro]

Bike is now at my local garage, sorry no pics.

Its the front right.

Unfortunately it was a simple case of poor materials, I rebuilt the calipers and the next day when I went to bleed the lot it simply snapped off.

The garage has tried to use rewind tools, it could be drilled but 99% of the time results in a damaged caliper so now looking for a replacement.

[2112]

What about a bleedable banjo bolt ? Saves a lot of hassle.

[pedrosgoro]

Never came across one, do you know of any reputable suppliers?

[Juvecu]

These are the bikes that use the same calipers as your AK7. Ignore the bits in the brackets at the end, it's just confusing. The correct year numbers are at the front of each line. This was taken from a Suzuki parts site.

2003 SV650 - FRONT CALIPER (SV650AK7/SAK7)
2003 SV650A - FRONT CALIPER (SV650AK7/SAK7)
2003 SV650S - FRONT CALIPER (SV650AK7/SAK7)
2004 SV650 - FRONT CALIPER (SV650AK7/SAK7)
2004 SV650A - FRONT CALIPER (SV650AK7/SAK7)
2004 SV650S - FRONT CALIPER (SV650AK7/SAK7)
2005 SV650 - FRONT CALIPER (SV650AK7/SAK7)
2005 SV650A - FRONT CALIPER (SV650AK7/SAK7)
2005 SV650S - FRONT CALIPER (SV650AK7/SAK7)
2006 SV650 - FRONT CALIPER (SV650AK7/SAK7)
2006 SV650A - FRONT CALIPER (SV650AK7/SAK7)
2006 SV650S - FRONT CALIPER (SV650AK7/SAK7)
2007 SV650 - FRONT CALIPER (SV650AK7/SAK7)
2007 SV650A - FRONT CALIPER (SV650AK7/SAK7)
2007 SV650S - FRONT CALIPER (SV650AK7/SAK7)
2007 V-Strom (DL650) - FRONT CALIPER
2007 V-Strom (DL650A) - FRONT CALIPER
2008 SV650 - FRONT CALIPER (SV650AK8/SAK8/AK9/SAK9)
2008 SV650A - FRONT CALIPER (SV650AK8/SAK8/AK9/SAK9)
2008 SV650S - FRONT CALIPER (SV650AK8/SAK8/AK9/SAK9)
2008 SV650SF - FRONT CALIPER (SV650AK8/SAK8/AK9/SAK9)
2008 V-Strom (DL650) - FRONT CALIPER
2008 V-Strom (DL650A) - FRONT CALIPER
2009 SV650 - FRONT CALIPER (SV650AK8/SAK8/AK9/SAK9)
2009 SV650A - FRONT CALIPER (SV650AK8/SAK8/AK9/SAK9)
2009 SV650S - FRONT CALIPER (SV650AK8/SAK8/AK9/SAK9)
2009 SV650SF - FRONT CALIPER (SV650AK8/SAK8/AK9/SAK9)
2009 V-Strom (DL650) - FRONT CALIPER
2009 V-Strom (DL650A) - FRONT CALIPER

So in short 2003 SV650 and 2007 DL650 up to 2009 are the same. The 2009 upper limit might just be because the site hasn't been updated.

[pedrosgoro]

Top Stuff, gives me a much wider search. Thanks for the info :-)

[2112]

Never came across one, do you know of any reputable suppliers?

http://www.ebay.co.uk/itm/New-BANJO-BOL ... 20d59c2a3d

Way cheaper than a new caliper  

[mjc506]

I've got a caliper you can have. It will need new seals, but I also have a piston/seal kit for it.

£35+post?

[greywolf]

It wasn't poor materials. Bleeder screws are hollow so break easily if overtorqued. Put the blame on the workman.

[Jacko]

These callipers are on just about every budget bike from the last 10 years. The Er6 uses them, as does the new GSR750, surprisingly. Although that bike has a stronger master cylinder.

[Juvecu]

The GSR probably weighs quite a bit less too

[Jacko]

211kg to the DL650 K7s 220kg, so not much in it.

I was very surprised when I test rode the GSR to see the callipers on what is a sports naked, but they are adequate, the stronger master cylinder provides more powerful braking than the Vstrom but I bet it'll get through pads quicker as a result.

[Iggy]

I expect the GSR runs a 5/8 master cylinder as opposed to the 14mm on the Wee. SV650 also runs 5/8 which is around 16mm. Not a lot of difference in size but reduces lever travel and firms up the feel. I've been running my Wee on a 5/8 master cyl for a few years now and rate it as a good cheap upgrade - plenty of secondhand ones about.  

Not noticed any increase in pad wear, just reduced effort required by the rider, or increased braking with the same effort depending on how you look at it.......  


Iggy

[pedrosgoro]

It wasn't poor materials. Bleeder screws are hollow so break easily if overtorqued. Put the blame on the workman.

It really was, the quality of the material was sub standard, almost too thin to the touch. I've removed and cleaned these things a hundred times, the one time I chose to rebuild the lot and it was a poor product.

[pedrosgoro]

Thanks again everyone, my local Suzi dealer has a bleed nipple which I am picking up tomorrow, I think I am then going to consider doing an upgrade on the calipers - I hear there are a few that can be done to improve performance.

[Jacko]

Thanks Iggy, interesting info. Might look at that if/when I upgrade the lines. Don't know how easy that'll be though as it has ABS.

[mjc506]

If you're going the route I think you're going, you'll need a DL1000 or DL650K6 (or earlier) master cylinder.

[greywolf]

It wasn't poor materials. Bleeder screws are hollow so break easily if overtorqued. Put the blame on the workman.

It really was, the quality of the material was sub standard, almost too thin to the touch. I've removed and cleaned these things a hundred times, the one time I chose to rebuild the lot and it was a poor product.

You may be comparing steel nipples to brass nipples. There is no error in manufacture I can think of that would cause the walls to be thinner than normal.