Author Topic: Front brake calipers "insulator"  (Read 740 times)

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Offline Kazawhaki

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Front brake calipers "insulator"
« on: December 31, 2018, 12:48:26 am »
Hey everyone, I'm looking for some advice on a rebuild of my front calipers. They're the standard set on my 95 Gtr but once I got the pistons out I can't seem to remove the insulator that sits inside the piston. They're in pretty bad shape anyway (chipped surface etc) and since I'm changing the pistons anyway I was hoping to fit new insulators while I'm at it. Does anyone know the part number for them or know where I could order them? Thanks again.

Online MAN OF BLUES

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Re: Front brake calipers "insulator"
« Reply #1 on: December 31, 2018, 01:14:41 am »
I'm at a loss about the term "insulator" please elaborate a bit more about the part.

the internal parts of the pistons, and seals do not show a p/n for the 'cage' that sits in there, which is what I'm assuming you are referring to. Those parts are combined with the pistons, and come assembled, and do not seam to be separately available here in the USA. Sorry.

parts shown here, on the Kaw Microfiche are as follows.

upper piston;
43020-1069   PISTON-COMP-BRAKE
43049-1057   PACKING,PISTON
43049-1056   PACKING,PISTON SEAL

lower piston;
43020-1068   PISTON-COMP-BRAKE
43049-1055   PACKING,PISTON
43049-1054   PACKING,PISTON SEAL

quantity of 1 each, per side required.
pay attention to part numbers, as they differ between the upper and lower pistons in each caliper.

so, if you are buying new pistons, the internal cage is already installed in them...
hope this helps.

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Offline Kazawhaki

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Re: Front brake calipers "insulator"
« Reply #2 on: December 31, 2018, 09:21:25 am »
Thanks for the reply. The bit I'm talking about is highlighted the arrow in this pic. I just don't see it shown in any of the replacement piston sets I've found online. According to the steps of the Clymer manual you have to remove the insulator which I assume to be the piece highlighted in the pic with the indented cross on the top

Offline Bud

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Re: Front brake calipers "insulator"
« Reply #3 on: December 31, 2018, 10:25:50 am »
I used Brake Crafter kits on my 1983 GL650 project.  Good stuff and has everything you need to do a complete job......including those elusive bits you were asking about.  HTH
https://www.brakecrafters.com/collections/2005-kawasaki-zg1000-a9-a20-concours/products/1994-2006-kawasaki-zg1000a-concours-front-brake-caliper-piston-seal-kit
2005 Kawasaki Concours
1982 Suzuki GS1100GK
1983 Honda GL650I SilverWing

Offline Kazawhaki

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Re: Front brake calipers "insulator"
« Reply #5 on: December 31, 2018, 08:56:45 pm »
interesting...
the link you gave for pads, also has a set of rebuild parts, pistons, etc... and those come with the plastic parts you noted.... that kit seemed oddly low priced, compared to OEM Kaw parts. But it may suffice. Let us know how it turns out.

https://www.brakecrafters.com/collections/1996-kawasaki-zg1000-a9-a20-concours/products/1994-2006-kawasaki-zg1000a-concours-front-brake-caliper-piston-seal-kit

I do however recommend using quality pads, like Galfer, EBC, etc.,
There have been quite a few "pad separations" with inferior pads in the past, including those from Fren

best of luck

« Last Edit: December 31, 2018, 09:02:27 pm by MAN OF BLUES »

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Offline connie_rider

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Re: Front brake calipers "insulator"
« Reply #6 on: December 31, 2018, 10:37:28 pm »
Kazawhaki, I don't know where your located?
Because you said you have a GTR, I suspect Europe?

Regardless of your location, your existing Caliper appears to be in very bad shape.
I suggest you buy a working set of known good calipers and install them.
Will probably cost you less in the long run.

Here is a set I found on Ebay {that includes hoses/pads/etc} for $73.
I easily found several that would fit your bike... These appeared to be in the best shape.
..
https://www.ebay.com/itm/2005-94-06-KAWASAKI-CONCOURS-ZG-1000-ZG1000-FRONT-BRAKE-CALIPERS-OEM-CALIPER/332972926770?fits=Year%3A1995%7CMake%3AKawasaki&epid=552439542&hash=item4d86bba732:g:9boAAOSwZddcH4~b:rk:33:pf:0#viTabs_0

Ride safe, Ted

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Offline Kazawhaki

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Re: Front brake calipers "insulator"
« Reply #7 on: January 02, 2019, 06:01:43 pm »
Sound advice Ted, yea it's a Gtr here in Ireland and the Irish weather doesn't do anything to help brake calipers to stay in good shape unfortunately. I've order those calipers you found on eBay as they worked out a lot cheaper and hopefully will get me back on the road again quicker without having to wait to rebuild both calipers. I can take my time to clean up my own set and maybe spray them up etc when I have more disposable time and more disposable income. Thanks for the heads up everyone who offered advice. Really appreciate it.

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Re: Front brake calipers "insulator"
« Reply #8 on: January 03, 2019, 02:15:44 am »
I thought about this for a few hours after you posted, and thought I'd be dropping the ball, if I didn't say this.. the link and parts Ted hooked you up with look super, but..
please take the time, and don't skimp on removing the pistons from them (the new ones), and completely cleaning the insides of the caliper. pistons, and existing seals (and even lines if you use them) with a high quality brake cleaning spray/solvent. Make sure to remove any trace of the fluid they were delivered with.. Brake fluid is extremely hygroscopic, and will suck up any minute molecule of moisture thru the lines that have remained open since they were removed from the donor vehicle.. this will in turn, degrade any fluid remaining into jello, and begin the internal corrosion process on the nice calipers you bought, rendering them rusty, and prematurely gacked up in short order..

once clean, reassemble them dry, and begin with the bleed process with fresh, sealed containers of new brake fluid and bleed accordingly..
hope all goes well, I just didn't wat to see someone "slap them on, bleed them, and expect perfection and longevity"..

best of luck,
ride safe.

30 YEARS OF KAW.....Rich R. (the other one..)  COG 5977  JUSTAMEMBAHNOW
and if you are gonna call me names... it's MR. Analdweeb if you please...

Offline m in sc

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Re: Front brake calipers "insulator"
« Reply #9 on: January 04, 2019, 12:41:28 am »
mob is right. some of the best money i spent on the concours is ebc 'hh' pads. worth every penny.

Offline Kazawhaki

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Re: Front brake calipers "insulator"
« Reply #10 on: January 15, 2019, 06:37:00 pm »
Thanks Man of Blues, that's sound advice also. The calipers just arrived at the house  about half an hour ago and I had a quick look and while at a cursory glance you'd think the calipers are spotless a closer look at the pistons shows some road grin and brake dust etc. Nothing too serious in fairness but no point lashing them on in a rush. May as well take the time to fully clean and inspect them etc before fitting.

Offline connie_rider

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Re: Front brake calipers "insulator"
« Reply #11 on: January 15, 2019, 08:13:10 pm »
Congrats,, Let us know how they wok out for you.

Ride safe, Ted
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Offline Kazawhaki

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Re: Front brake calipers "insulator"
« Reply #12 on: January 16, 2019, 05:14:48 pm »
Any suggestions on a high quality brake cleaning spray?

Online MAN OF BLUES

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Re: Front brake calipers "insulator"
« Reply #13 on: January 16, 2019, 07:07:32 pm »
Any suggestions on a high quality brake cleaning spray?

pretty much every autoparts store sells it, I use the CRC stuff, just don't expose it to HIGH heat, (like flame) and don't smoke when using it.... not because it's flammable, but because any of these cleaners "break down" and create Phosgene gas when the atmosphere is drawn thru a cig, or heated... it is extremely toxic, and causes really bad side effects...
It's totally safe to use, and be around in it's "normal aerosol form", only when it "burned" is when the gas is formed.


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Offline bajasam

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Re: Front brake calipers "insulator"
« Reply #14 on: January 17, 2019, 01:12:12 am »
wear some goggles when spraying that crap, it burns like hell if it ricochets a stream back into your eyes,its a high velocity stream leaving the can.

Offline Kazawhaki

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Re: Front brake calipers "insulator"
« Reply #15 on: January 17, 2019, 06:06:59 am »
And it's safe to spray through the rubber brake lines to clear out any moisture?

Offline m in sc

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Re: Front brake calipers "insulator"
« Reply #16 on: January 17, 2019, 03:42:11 pm »
... id blow out with compressed air if the lines are disconnected.  wrap a rag around the 'outlet' side.

Online MAN OF BLUES

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Re: Front brake calipers "insulator"
« Reply #17 on: January 17, 2019, 07:25:09 pm »
And it's safe to spray through the rubber brake lines to clear out any moisture?

yes... and followed by blowing clean compressed air, to remove the residuals.

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Offline Kazawhaki

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Re: Front brake calipers "insulator"
« Reply #18 on: February 09, 2019, 10:16:44 am »
Thanks for all the help and advice. New calipers cleaned, fitted and bled now. Tried to post pics but seems to not work for me for some reason.

Offline Kazawhaki

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Re: Front brake calipers "insulator"
« Reply #19 on: February 09, 2019, 10:18:07 am »
Second attempt

Offline Lee

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Re: Front brake calipers "insulator"
« Reply #20 on: February 09, 2019, 07:15:47 pm »
As an aside, have used a Brake Crafters kit years ago on a Yamaha Virago and recently on my 87 C10 for all three calipers. Have no complaints save one brake bleed cover bit the dust on install. I could have been ham fisting it in all fairness. The other two were fine. Like it that the kits come with pot of red brake assembly grease. My Virago calipers were rebuilt many years ago now. Did use premium pads on both bikes however after shopping around price comparisons. Also did not need pucks on either bike just rubber parts. No complaints as yet.

Offline Lee

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Re: Front brake calipers "insulator"
« Reply #21 on: February 09, 2019, 07:20:05 pm »
Bye de bye? Any recommendations on caliper paint? The silver purchased from AutoZone designed for calipers did not hold up at all. Spent a exceptional time on prep. Was extremely surprised at how poor the adhesion was.

Offline Boomer

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Re: Front brake calipers "insulator"
« Reply #22 on: February 10, 2019, 04:53:15 pm »
Caliper paint needs a good quality etch primer base.
Then apply the top coat, wait until touch dry and then bake at 60°C for an hour or 2.
George "Boomer" Garratt
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Offline bajasam

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Re: Front brake calipers "insulator"
« Reply #23 on: February 11, 2019, 04:28:42 pm »
Bye de bye? Any recommendations on caliper paint? The silver purchased from AutoZone designed for calipers did not hold up at all. Spent a exceptional time on prep. Was extremely surprised at how poor the adhesion was.
almost always the reason for paint or adhesives not bonding will be lack of proper prep and cleaning.

Offline Lee

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Re: Front brake calipers "insulator"
« Reply #24 on: February 11, 2019, 07:16:08 pm »
Yep would agree on prep except.
In this case painted repair to right foot peg in same silver at same time with same prep. No problems with it. Think it may be paint adhesion was lost while bleeding brakes. But just a guess here. Maybe caliper paints are not brake fluid resistant.