Delboy's Garage, Suzuki Bandit Brake Caliper (Full Rebuild). 

Just finished the rear caliper rebuild , all working fine , thanks for your great video and advice Del.

Thank you for all your videos! Looked around RU-vid for something to help me strip down and rebuild the rear calliper on my Piaggio scooter. Not convinced with other videos saying to use sandpaper to clean the pistons up, so was pleased to find your channel! Managed to get my calliper all sorted with new seals and pistons gleaming after a polish with Autosol. Your expert tuition really helped me. I'm now watching your other videos as I'm really enjoying learning from you! Cheers!

Hi ya, just rebuilt both front calipers again following your guide, and now I have brakes like little mofos! I think by following what you've put in different vids I've saved nearly £400 already on labour costs. You deserve a lot of respect for what you do and the help you give... Thank you

Fantastic video! Thank you for going over absolutely everything in an easy to understand format at a perfect pace. Well done.

This is so good in that you show how to sort out really messed up brakes. I've found them to be a bugger to work on but I reckon I won't next time. The bit on bleeding was particularly useful. Thanks a lot Del.

Your videos are really good mate, thanks a lot for taking the time to make them and put them online for us to learn from.

This helped me a hell of a lot. I dont have my bandit on the road yet but i needed to do this on my scooter as the brakes where binding. After watching this i followed step by step and now my brakes are spot on. Thanks for the great tutorial Del and keep them coming.

Great video Del! I finished cleaning and rebuilding a set of calipers for my project yesterday with this video showing my how it is done, thanks mate.

Best tutorial on this subject. Rear calliper are one on the most neglected yet important parts.

Hi Greg, that's great news, i love to hear that someone has actually used a video to help learn a bit about their bike...that's exactly why they are there... well done on getting it done yourself, good luck with it and than you right back for taking the time to watch and comment... stay safe.. Del.

Hi Andrew...stupid design or what?, but its an easy fix, and once they are drilled out, you can slip the pads out in a moment the next time you need to.. thanks for your kind comments mate, i appreciate the support.. Del.

Thanks for the in-depth guide! I was able to rebuild my rear and front calipers with no problem thanks to you, delboy. For the record, my pins came out no problem on the rear caliper - it just took a little twisting with locking pliers. Maybe pressing down on the brake pads to relieve pressure helps, or maybe it's just the difference in environment. In the southern U.S., we don't get much snow, so we almost never have salt on the roads to get onto vehicles and mess things up. Either way, it was a huge relief. The brakes are as good as new now!

Thanks for taking the time to make these videos, very helpful! I did the rear pads on my new to me bandit a few weeks ago and as you say the pins are very hard to get out, mine were pretty much welded in, even after drilling the calliper needed a lot of heat to get them out! Also noticed my dust seals were poking out slightly so thanks to your video I'll be rebuilding fairly soon, great tip on the grease to get the pistons back in, I really struggled with that when I rebuilt my last bike's rear calliper . Cheers

This video was a great help when sorting my Bandit rear brakes. We actually managed to get the pins out intact without drilling the other side of the calliper! Thanks so much for the tutorial!

Top video, nice to see someone do a video of this type of job without a full set of garage spec tools. More importantly good to see it done to proper used on the roaded grudded up callipers. Nice one, thank you

Followed these steps Del today and rebuilt my bandit caliper on the rear. Wonderful video mate and got the job done with ease. Top video my friend 👍

Matt, you've learned more in that job that you would in a whole term at college, dont beat yerself up mate, every step is a new piece of experience....well done for getting stuck in and good on you mate... now go out and enjoy your hard work...Del.

Discovered a stuck piston this afternoon. Remembered watching this how to vid many months ago, so ordered the bits and hopefully can restore my 36 year old Brembo caliper in the next few days. Chrome covered pistons have gone rusty around the edges. Replacing with alloy. Your brilliant explanation gives me confidence to save a few pounds.

Hi Lewis, well done Sir, glad you got that done and glad the video could help you. this is exactly why we load them up, times are hard and it's great to help our fellow bikers save a few sheckles ... just make sure you double check everything after a few miles...good luck and ride safe, Del

Absolutely love the way you explain how to do stuff step by step. Thank you and your missus for your time and effort and just don't stop please. It was pleasure to watch your video.

Great videos dude, with your help im well on my way to completing my streetfighter build, I have always loved to do things my self, but never had the knowledge or confidence. With you guides I have a better grasp on things and have found that i am capable of doing it myself. This is great, im proud I done it myself and saved a load of cash.

Exactly what I doing, and exactly the same problem with the dust seals, my pins did come out (huuraaay !!). I like the tip for cleaning and bleeding. Great video.

Del been watching and following your video for some time now, this one I saw some time ago, but finally got around to doing the rear caliper on my gsxr600 (same rear caliper as the bandit) . I had a fresh viewing of this video again, and tackled the overhaul of rear caliper and got it all done. Thank you for these videos, definitely the best and most comprehensive how to motorcycle mechanical on the net.

Have to say your vid's are excellent. Precise and no fannying around. Dare I say it, the best bike maintenance vid's on youTube. Keep up the great work. Thanks Nick.

Now you see what a 30 years of experience can teach you. Thank you to share this with us simple souls. I've learned alot!! Keep going man.

Thanks for taking the time to do this video, it's a great help for me in my prep to change the pads and check the rear calliper on my "new" 2000 Hayabusa. A really great resource. Thanks again 👍

you are definitely the BEST instructor i watch some videos and i think i cant do that or it looks to much trouble but your videos make every thing seem simple or at least dooable i cant thank you enough

You're very welcome buddy, its great to spread the things we know and help keep our bikes safe and on the road without paying the stealership to do it for you.... keep at it chap.. Del.

a top bloke,, watched your videos many times before doing jobs on my bandit its saved me loads of time and money,,,,,keep up the great work bro your a legend

Bugger the heat and quench, a light soaking of wd-40, some gentle patience, persuasion and the giant truckies flat head screwdriver I found on the road years ago has kicked a goal. I can't believe how much crud has formed in there! Thanks again dude, you're a champ, best of luck with the numb nuts PBC also!

Cracking video as usual - pistons came up lovely when polished. Over the past two videos I've learned allot about brakes and what is proper essential maintenance. Cheers Del.

Yep, bleeding brakes is always a knack...try the 'upside down' method if you can get them off the bike, it works instantly and gives a rock hard lever too.... thanks for watching mate.. Del.

Another great vid, you seem to have a knack of putting up videos of things I am just about to do and this really helps as I am learning as I go along. Thanks again for passing on your knowledge.

Thanks,first job on Saturday morning is my rear caliper as it is sticking on.Followed your front caliper service and it saved me about two hours compared to when I have done the job before.Excellent more power to you. Cheers Graham 1200 Bandit rider.

I realize why I like your videos, it's because you sound like me when I teach, making sure details are covered. I discovered a math teaching system an know it works, but I need more great minds to learn "Why"! Thanks, I laughed when you used the clamp on brake peddle, an I use the sucking up brake fluid with just tube an mouth method. But, Great idea I'm definitely going to start using is holding pressure on peddle over nite for small air bubbles! Haha, Thanks! Tim

Thankyou Delboy. Great techniques and no contact brake cleaner. Though this video was 12 yrs ago

Thanks Glenn, glad you like the vids, appreciate your watching! Del

P. Del, this video has been very useful to reinforce that I know what I'm doing and rebuilding a caliper isn't beyond my ability. I've got a 1994 Funduro which is generally in good condition. though the brakes have been neglected. You would have been mortified with the colour of the brake fluid! Anyway today I successfully removed the pistons from the caliper. There was no dust seal. OMG. Thanks for the great video. Off to watch your latest about the Kevlar tail. Cheers 🍻

You are a hero! I bought an old XJ600 (1991) to learn the misses how to drive before taking the exam. As it always go with old bikes, they have their little problems which can be solved with a bit of love, but you have to know how. I can't thank you enough for your videos, because I just restored the old rear brake (fully seized and wouldn't go back) with nothing more than 30 euros (the piston needed to be replaced) and a lot of time!

John, thats great news mate, and the exact reason we started this channel. glad it went well for you, good on you for gettin stuck in....take care, Del.

Thank you very much for this vid and the other bandit vids you've done. I've just got the same problem with my seals poking out when trying to clean them as per the vid for cleaning your front calipers, I then had a look and you had done this vid giving me the massive confidence I needed to tackle the complete rebuld. Cheers buddy.

That sounds a kewl buke buddy... i Love the old 850 triple, a really amazinf sound, specially on an open pipe.lol.. I seem to remember the XS brake calipers were 'rotating' calipers, they have wedge shaped pads...and the pistons can get jammed if you dont press them in straight... Good luck with it mate, and thanks for your kind comments... ride safe.. Del.

ok cheers. I've just finished rebuilding the caliper now (3 hours not bad for a first timer haha), thanks a huge amount for the video, needed your tip for knocking out a stuck piston, and great tip for polishing! brake works like a dream now, thanks again

Thank you for a great video. I am doing this job on my Bandit and this was really helpful. I just wish beer was as cheap now as when you made this video.

Thanks mate, appreciate you watching and taking the time to comment...ride safe, all the best, Del.

Yeah cheers Del, I was spewin'! I watched this, then thought how grand it was my 88 GSXR didn't have one. I'm refurbishing my rear caliper tonight, and have disappointingly realised it is indeed the same Tokico unit. Thanks a million for the tips, (3:18) I'm feeling lucky! Have a good weekend, mate!

I don't know how RU-vid knew, but I'm preparing to work on my calipers, 6 pot tokicos on my old J2 ZX6R (I believe known to seize at the slightest whiff of dust). I've only been riding a year and am psyching myself up for it. Watching you fearlessly approach these jobs is great inspiration. I'd like to thank you dad for teaching you, so you could then share the knowledge with us. This channel is pure gold! Thank you!

Excellent Steve.. thats exactly why i post them up, im glad it helped you out... take care and ride safe.. Del.

im only 5 mins in and already wishing my boss had a fraction of your gift for sharing your knowledge. Thanks mate, you've given me the confidence to dust off my mothballed RGV :)

Hi Dell, i did the front 6 cilinder calipers today on my 2004 bandit 1200. And i want to thank you for the tips on placing the new seals. Somehow i could see how to put the new ones in because on all 12 i placed them in the right way on the first try.. It took me about 4-5 hours but i'm really glad it's done now. Keep up making great videos!!

Thanks ever so much for tacking time to do a vid on calliper a , I've just bought a bandit of eBay and disks are binding now with some heavy braking on and off trailor the garage said they had put new pads in but I can tell they haven't cleaned em up properly so now with your help il do it myself like you say it's worth doing and maintaining them cheers mate keep it up ant from Wales

hi del n penny awesome vids keep up the good work....last mot on the zx6r j1 he told me that the pistons in the calipers were strugling to come out not in a smooth operation....the bikes coming out after the winter in bed soon and after watching the above video you have given me the total confidence in doing the job myself waiting for the seals as we speak...once again keep it the 2 of you😊

Love watching your videos. Have learned a lot in a short time. Great little tips and tricks. Appreciate it.

did this on my zx9r, rear brake was binding, cleaned it up but took me about 2 hours to bleed after constant swearing and kicking the cat etc, walked away, came back and took the bleed nipple out, cacked up was not the word, no cap ont nipple, it was so shit up that I couldn't see the bleeding holes, i cleaned it up with brake cleaner and a panel pin and a bit of elbow grease and it bled perfectly, covers for all of my nipples have been ordered, oo-er missus, good work, keep it up mate, paul.

Del, cant thank you enough for the drilling the backside of the caliper them pins are the bain of my life, Thanks for the step by step guilde plus products can use to clean. Bandit 600 Blackpool

Hi Del I just like it give you a big thank you for your videos they've save me a heap of money I've just finished a calliper rebuild this morning all thanks to you and your videos all the best and keep up the good work. John

Cheers for the amazing video. Very informative and easy to follow. Just finished refurbing my front and rear calipers and I don't think I would have even attempted it before watching this. Brakes work like a dream now along with my confidence that I can tackle these tasks myself without the need of spending £££'s to a mechanic.

Hello Matt, wow isn't it amazing how those labour hours add up?! Once upon a time fixing up your bike and doing those basic housekeeping based maintenance tasks were all part of the fun of owning a bike..but these days bikes are so much more reliable and dealers are so much better at stepping up and taking on any task we need, but boy do they charge! Keep at it, mate, and thanks for your kind words.

Well done John, glad you got it sorted mate...have a good time away..take care. Del

Hi Gary, well done on buying a Bandit, they are a brilliant all rounder mate..all i can say to your request for advice. is 'stay on top of it', little day to day maintainance saves a bundle on servicing..if you keep the bike tip top all the time with chain lube and adjustment, tyre pressures, cable and lever adjustments etc..then at service time its just oil and filters..easy..keep it all up to date as often as you can and the bike will reward you with loads of safe miles...take care buddy, Del.

Good to see you back sir! Really good video. Your How to videos are some of the best I have seen, the level of detail, showing tips and tricks, to make the job easier. Never seen a caliper split half like that. Wanted to also mention that your camera operator was doing an excellent job! Tell her to keep up the good work!

Thanks del, just sorted it I was in a bit of a panic, I thought I'd messed the suspension up or something. The rear caliper was a nightmare, fluid went every where, one caliper bolt seized but local mechanic got it out for a fiver, took about 2 hours to bleed and then stupidly I used an old brake pad instead of a licence plate in between the pads.. it slipped out a little and destroyed them. But you learn from your mistakes and top blokes like your self.. so thank you again

Yep, about 09.15 this morning, Got a replacement main seal and the chap in the shop said not to bother, Gave me a small tub of red grease FOC and to try that. Great videos btw thankyou so much :)

hi mate.well done for getting stuck right in there and doing it yerself, good on you mate, 90% of bikers run a mile at the thought of stripping brakes....OK , the 'bar' you talk about is called the "Torque Arm! and its job is to stop the caliper rotating round with the disc when you apply the brake..with the caliper fitted to the mount, loosen off the axle then back off the wheel adjusters and push the wheel right forward, then it will line up, loosen the front bolt too and it'll all fit again.

This is gold! My k1 gixxer 600 rear caliper is seized. The caliper looks similar if not the same! Was about to buy 2 new pistons. Thanks Delboy!

Hi Rob,the best tool for this job is a good quality, sharp, 10mm chisel, use it to tap the bearing cups out of the head tube from the inside (the sharper it is the better it will catch the little lip they leave for you to bear against) & to get the bottom race off the stem just lay it on it's back on a piece of wood and tap the chisel in between the race the bottom yoke alternating side to side until you drive it off..hope that helps, mate, Del

Thanks for another great video Del. Just fitted new braided hoses to my GSX750W and did a brake seal change as well, this video was a great help!

Hi Mark... brak cleaner is developed to be used on all brake parts safely including the pads.. its a vapourising spirit and not an oil...so dried out grease and slime a treat.. and is a very good periodic tool for winter use...do the worst with soapy water and a hose as in my brake washout video...then hit it with the brake cleaner for a fine finish...! good luck, Del.

i just completed this on my scrambler, thanks man...it went so well w/ no surprises thanks to you...good trick for quickly bleeding before reinstall of caliper.

Hi Del Great vid. I've got the same brakes on my RF9. The stuff you put out in had been invaluable in keeping my 20 yr old bike on the rd and my safe. The brake on my ZZr600 are still really sharp after a rebuild last year. I wanted to point out that the white powder stuff inside the callipers is probably aluminium oxide not rd salt, however the rd salt will be mainly responsible for corroding the aluminium callipers to create the aluminium oxide. Knowledge is power. I also have saved a hell a lot of cash thanks to you, and can now buy beer or more bikes, or what the hell else I want. Cheers

well done Jim, thats great news, it encourages us to know that the videos are being useful... ride safe chap.. Del.

Video helped me loads! Just done my rear seals as the tracks for the seals were completely gunked up. Cheers fella

@MrGarethwyndavies Thanks Gareth, Penny Pitstop is my camera genius, and says thanks for your kind comment. glad you liked the video..

Delboy great video as are all of your vids. This video saved me a massive amout of cash as the garage qouted me £500 to do front seals and steering bearings. I got the parts off fleabay at a total of £50. Cheers

Delboy you're a star. I was just doing the rear calliper on my Pan Euro, and was searching around to find the best way of cleaning the brake pistons and came across this. I had a tube of Autosol in my hand at the time!!! (just wasn't sure if it was ok...). Based on your tips I'll crack on

Cracking video fella. I had a scary moment on my bandit at the end of the summer!! I realized the back brake was really poor and have decided to overall the calliper. I've ordered a kit and a braided hose. Thanks to your video, I'm gonna give it a go!!! cheers Fella.

superb vid Del,took my back calliper off covered in salt seals popping out followed your video cleaned had to drill back of the pins job done thanks.

Appears to be the exact same Tokico rear caliper as used on the Kawasaki ZX11D. Thank you for the great video and tips. (BTW, my pins came out with naught more than my fingers; but to be fair, a shop replaced the rear pads a few years ago and no road salt in California!) Cheers, sir!

Thanks; the videos are a massive help; I've always done stuff on the car (engines/alternators) and generally the haynes gives you 90% of the right instructions, ingenuity and a piece of 2x4 and a lump hammer usually dealing with the rest, the same can't be said for bikes. Keep up the amazing vids; looks like I'm going to be busy overhauling, bolt by bolt :D

Thanks to your awesome vid i have successfully rebuilt both my callipers on my Gs500 and saved me a few quid. Many many thanks del. lewis

Thank for your kind comments mate, and i get what you say on the videos, they are a different mind set to us. With the brake pad pins.. its cool to split the caliper to get the pins out..but only when you are doing the seals too..when you just want to slip a new set of pads in, the holes come in real handy.... and yes.. for £3 you should have bunged some new seals on DOH..! Bleed it with the systme upsidedown. the air come to the caliper naturally, and then use the fluid to push the pistons out.

Thanks for watching mate, i appreciate the support... Del.

Sold.. a brew and a yarn is spiritual practice buddy....glad to be of help,,,take care aye.. Del.

This was a really good video, you never think about these things like that type of dirt and grime in these, take em for granted too much, it really makes me look at the common sense portion of the maintenance on the bike. You always wait till it's too late and then it's one costly and two difficult.

Superbe Video's you make certainly helped me a lot thanks for taking the time to make step by step maintenance of the brakes.

Hi Moonfleet thank you for the video its very informative and the time you take out to do this is very much appreciated!!! I have a Suzuki bandit GSF600S 1999 model and i can see the rear caliper permenantly on the disc so I guess it needs changing

Thanks for this one did my first calliper rebuild following this and it feels awesome, cheers

Great video. Love ur approach to working on bikes.

Greatly appreciate your video. Now I will be able to rebuild the caliper on my 1975 Yamaha xs650. Thanks a million

The fluid pushes equally on the back of all pistons, but sometimes the free ones will pop out leaving the stuck one behind, the trick is to hold the moving ones in with a G-clamp leaving all pressure to push on the back of the seized one... it is very rare that this will not work, but if it's stubborn, then dip the caliper (still connected to the hose) into red hot water, this will expand the caliper casting quicker than the steel piston and help free it off... hope that helps, good luck, Del

Excellent video mate, gave me the confidence to tackle my own which i did successfully last night. Keep up the good work!

Thank you for that.I recently bought a b12 and it has this exact issue. Now it will be an easy fix. Great video Del.

The metal polish trick for the pistons is a great tip. Cheers !!!!

I know the guide you refer to, and I'm pretty sure they can be un-bolted and removed, but if not, it isn't hard to bleed it horizontally, which is still better than trying to bleed downwards...air doesn't like going downhill LOL...other than that the trick is to build up pressure with 2-3 pumps, hold the peddle down & then open and close the nipple to release the pressure, truly is just a knack and trial & error, good luck with it, mate, Del

Hi Del and Penny Brilliant - don't know how I missed it on your channel. Those pins are a real piece of design work!!!! Thank for you help, and looking forward to further installment of Project Bandit rear end. Keep up the good work. May be you should take on Mr Haynes at his own game, a real life how too's are far better than - refer to this chapter, that chapter and the other. Thanks again Rob

Hi buddy, well it's a relief to know it's not leaking from the seals - bleed nipples can sometimes fail, you are relying on a tapered seat, which has to have 100% clean seal, sometimes in the bleeding process a tiny piece of debris can get between the chamfered faces and hold them apart, this will certainly cause it to leak..brakes are always a challenge & no 2 jobs are ever the same - hope that helps a bit, mate, sounds like you are getting there! Del

Thanks mate, appreciate you watching. Del.

Another win, Del, and I will keep that handy in case it's needed on my own Bandit. Canadian winters are much too harsh for riding for the most part, but still...

Hi Sammy. Thanks for your kind comments, it been useful to so many new riders that its developed its own momentum...if we can save riders a few bucks, and keep our new blood from making the silly mistakes that can get them hurt and cost them money, then thats what biking is all about, thanks for watching mate, and taking the time to comment... Del.

Thanks Ron, good to hear from you buddy, thanks for watching, del.