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Recommendation: The best brake caliper piston remover tool kit!

Started by Evans Ward, July 01, 2023, 02:13:56 PM

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Evans Ward

Wanted to share this with all my kindred spirits here! I've used 3 different tools and about 5 different methods to remove stuck brake caliper pistons over the past 9 years rebuilding/ refurbishing over 140 different brake calipers.  :undecided:  :gentleman: What you don't want to do in removal is to use any pliers/ grips on the outside of the brake piston  :rant-1:  as you want that surface area as smooth and clean as possible.  :love:   You can also say good bye to the messiness a grease gun makes and good bye to using compressed air which may turn your piston into a slug projectile!   :ninja:  Bye bye to heat and penetrant oils. The plier type tool that you find at the auto parts chain are best used with automotive purposes and not that effective. The kit that I have pictured was about $60 and fits an assortment of brake pistons on motorcycles. The assorted sized pieces expand at the bottom which will be at the deepest point in the brake piston. To make it expand you tighten the 2 pieces with handles. Once tight, most brake pistons will come out with a 2 way back and forth twist. For frozen and seriously stuck brake pistons, you screw in the long slide handle to "pop" out the brake piston. I haven't found a brake piston that I can't remove with this kit. I don't have a link to where I purchased it but do remember it was from an ATV store. Also, with the blue/ gold spot Yamaha calipers; you need the correct tool to get the anodized caps off. I've pictured these also. You just use a wrench or socket then. Hope this may help someone! :rimshot: 
1984 Yamaha RZ350
1976 Suzuki GT750
1972 Kawasaki H2 750 Mach IV

The Red Scourge

That's pretty slick.  I usually drop a socket into the back of the piston and use a ratchet with an extension on it to rotate the piston.
'76 Yamaha RD400C
'71 Kawasaki G3SS
'88 Honda CBR400RR
'90 Yamaha FZR400/600 hybrid

SoCal250

In my research for tools and methods to remove stuck pistons I came across a guy who was using that slide hammer kit. Seems like it should work pretty well.
75 Yamaha RD125B   75 Yamaha RD125B (project)
75 Yamaha RD250B   75 Yamaha RD200B (project)
73 Yamaha RD350     77 Yamaha RD400D   79 Yamaha RD400F  
91 Yamaha TZR250R  89 Yamaha FZR400   05 Yamaha FZ6   
05 Yamaha XT225TC  82 Honda MB5  02 Aprilia RS250 Cup (sold)

Kawtriplefreak


pidjones

I don't see grease as messy. You still have to clean all of the built-up brake fluid crud out. Grease just wipes out with rags and kerosene or diesel. 
"Love 'em all.... Let GOD sort 'em out!"

The Red Scourge

'76 Yamaha RD400C
'71 Kawasaki G3SS
'88 Honda CBR400RR
'90 Yamaha FZR400/600 hybrid

rodneya


Evans Ward

^ I bought that one too but didn't like it either.

Yes, the link to Amazon is the set I have!
1984 Yamaha RZ350
1976 Suzuki GT750
1972 Kawasaki H2 750 Mach IV

SoCal250

For the stuck pistons I just worked on, that blue MotionPro tool above would have done nothing. Also, I bought these pliers and they're only useful if the pistons are nearly free. https://www.chapmoto.com/bikemaster-brake-piston-puller.html If the piston is stuck the plier gripping surfaces will just scuff and wear smooth.
Even the sockets with a ratchet extension wedged into the pistons did nothing until I applied heat and cold. And even then it was a real struggle!
75 Yamaha RD125B   75 Yamaha RD125B (project)
75 Yamaha RD250B   75 Yamaha RD200B (project)
73 Yamaha RD350     77 Yamaha RD400D   79 Yamaha RD400F  
91 Yamaha TZR250R  89 Yamaha FZR400   05 Yamaha FZ6   
05 Yamaha XT225TC  82 Honda MB5  02 Aprilia RS250 Cup (sold)

RustyRD

Evans I just noticed you are in Ga..I am not far away, over in COLUMBUS  woohoo

Evans Ward

Quote from: RustyRD on July 05, 2023, 10:58:09 PMEvans I just noticed you are in Ga..I am not far away, over in COLUMBUS  woohoo

Very cool Rusty! About to send you a PM.  :wave:
1984 Yamaha RZ350
1976 Suzuki GT750
1972 Kawasaki H2 750 Mach IV

kpke

Nice one Evans.

Like the Dellboy YT link, my favorite YT channel has the same socket and extension trick.

https://www.youtube.com/c/KensGarage1
Hord of RZ350's
RZV500 R6 Suspension and Bodywork
R1 LE #158

Evans Ward

Very cool Ken! It's all in the twist as you demonstrated.  :thumbs:  :righteous:
1984 Yamaha RZ350
1976 Suzuki GT750
1972 Kawasaki H2 750 Mach IV