Hi all,

Have done a thread on this years ago on a Gen 2 busa, but a friend’s Fazer has sticky/rubbing brakes and a few of the pistons are sticking badly, so we’re going to remove them, clean and polish them and replace the seals while we’re at it, well overdue anyway the bike is 2009.

Just want to touch on the main points here to see if I’m missing anything, the process was fairly smooth on the busa (except for the pain in the ass bleeding it afterwards) and I don’t think there’s too much that will be different on the Yam? Basic 4 pot set up.

– Remove caliper from disc
– Remove pins and pads
– Piece of wood between pistons, hold one side down, remove pistons on one side, then on the other (pump them out with brake lever and fingers, don’t have compressed air option)
– Secure brake lever in ‘on’ position to keep master cylinder closed and full of fluid (is this correct/necessary?)
– Detach brake lines and remove caliper from bike
– Empty fluid and remove old caliper seals (2 per pot, internal fluid seal and external dust seal)
– Clean pistons with brake cleaner, remove build up/corrosion, polish if necessary
– Clean caliper, bleed screws and especially grooves for seals, using toothpicks, soft tools etc and brake cleaner
– Ensure all parts are dry and clean, reassemble, using red grease when bedding the seals
– On the busa the internal fluid seal had a specific direction, it was very subtle but the inner edge was slightly wider than the outer edge, as you pulled your finger down out of the pot you could feel a lip, but running your finger upwards into the pot there was no lip. A lot of conflicting info online on this one, can anyone confirm if this is the case on a 2009 FZ6 S2?
– Reattach brake lines, new copper washers for the banjo bolts
– Install pads and pins, reattach caliper to the wheel
– Do not have a vaccum bleeder so standard bleeding process, top up reservoir with new fluid, pump brake lever to build pressure, release bleed valve, repeat until no air seen from bleed valve and firm lever pull.
– Don’t allow brake reservoir to empty while pumping, top up to mark when finishing.

The bleeding process took forever on the busa as there were pockets of air in the calipers that took forever to displace, any tips for avoiding this?

Cheers all.

:thumbsup2: