Showcasing Our Expertise: GSX-R 750 Brake Calipers Refurbishment

We thought we’d take the time to share with you the Suzuki GSX-R 750 brake calipers that we’ve just refurbished in our workshop. These Tokico calipers were fitted to the GSX-R 750 back in 2004 and were some of the first radially mounted brake calipers ever used. Even by today’s standards, they remain excellent brake calipers. The braking power these calipers produced was superb, comparable to the GSX-R 1000 calipers, though they were mounted to a smaller disc.

The Importance of Safe Braking on Your Motorbike

The importance of safe braking on your motorbike shouldn’t be underestimated. We’ve all been in situations where we’ve had to brake harder than we’d like to avoid the car that “didn’t see you.” At Powerhouse, we are passionate about making sure your motorbike stops like it should.

The Need for Regular Maintenance

Suzuki recommends that the calipers be rebuilt every three years. The calipers we’ve just refurbished had never been serviced since the bike was new in 2004. Unsurprisingly, they were binding slightly, causing the bike to fail its MOT.

Our Comprehensive Suzuki GSX-R 750 Brake Caliper Refurbishment Process

Step-by-Step Breakdown:

1. Caliper Disassembly:

   We started by splitting the brake caliper halves and removing the seized pistons.

2. Cleaning:

   The original seals were removed to examine the seal grooves, which, as is often the case with Tokico calipers, were full of corrosion. We scraped out the corrosion and used a wire Dremel brush to clean the remaining residue.

3. Washing:

   The calipers were then put through our parts washer to remove the accumulated brake fluid and pad dust from 20 years of use.

4. Re-coating:

   The casings were media stripped and re-coated with our specialist caliper paint, then oven-baked to harden the finish.

5. Finishing Touches:

   Once removed from the oven, we milled the ‘Tokico’ logo to maintain the original look. After a final seal groove clean, we fitted a Brakemasters™ seal kit (click here to find out why we choose Brakemasters™ seals). The old pistons were pitted, so we fitted stainless-steel pistons which slid in perfectly, and the caliper halves were fastened together with stainless joint bolts. Bleed screws were fitted, and the calipers were pressure and function tested to ensure the pistons were moving correctly and the calipers were holding pressure.

Cost and Service Options

The labour cost for our Full Refurbishment service on these calipers is £62 per caliper. We also offer a mechanical rebuild service for £38 per caliper labour. For this project, we used the Brakemasters™ piston and seal kit, which costs £164.95.

DIY Refurbishment Kits

If you prefer to service your brake calipers yourself and have the necessary knowledge and equipment, visit our shop. We sell all the Brakemasters™ products you need for a DIY refurbishment.

(You can get helpful tips from our ‘How to rebuild brake calipers‘ page – Which includes a video).

Get in Touch

If you need help servicing your brake calipers, please get in touch with us. We are here to ensure your bike performs safely and efficiently. Take a look through the links below to find parts for your GSX-R 750 – Or visit our shop for components for your bike! You can also find us on eBay!

Suzuki GSX-R 750 Brake Caliper Refurbishment

At Powerhouse, we’ve been the world’s leading specialists in motorcycle caliper refurbishments for over 13 years. With unparalleled knowledge and expertise, we ensure your Suzuki GSX-R 750 performs at its best. For peace of mind on every ride, send your calipers to us for a professional service. Trust the experts!