Join Date: Jun 2014
Location: Ann Arbor, MI and San Miguel de Allende, Mexico
Help - Rear Caliper Dust Seal and Missing Parts
Sorry about the length of this. I've discovered a few issues with the rear caliper on my 2014 DL1000 and I need some advice. The bike has about 35,000 kilometers on it and I don't have any details re: its service history outside of routine service during the warranty period.
Back story: this bike is at our second home and winter getaway in Mexico. (Sooo glad to be here given the snow predicted for Ann Arbor!) I purchased this bike when we were here in July and only had it a few weeks before we returned to Michigan for the rest of the year. I knew it was going to need a chain and sprocket set when I bought it, so I brought them with me when we came down here last week.
While going about installing the chain, etc., I gave the rear caliper a good look while I was in the neighborhood. Good news: the pads are virtually new. But wait, bad news... what's that rubber o-ring poking out there? It looks like the shop that did the brake pads didn't get the dust seal in the groove in the caliper properly. This is #3 on the parts fiche, the first o-ring. And comparing my caliper to the parts fiche and shop manual, parts 16 and 17 on the fiche, the "insulator" and "shim," are missing.
I tried gently pushing the dust seal back into its groove without removing the piston, but no luck. The piston is going to have to come out to get it reinstalled. And it looks like the o-ring might have gotten twisted, so it's likely that it will need to be replaced, anyway.
I've never pulled caliper hydraulics apart myself. The shop manual says to remove the caliper and push the piston out with compressed air. I don't have access to compressed air here. Is it okay to get the piston out by leaving the caliper connected to the hydraulics and gently pressing on the brake pedal to push it out?
When I disconnect the brake line or push the piston out with the pedal, how much fluid will I have to deal with? Just the rear reservoir or the entire ABS system? I'm guessing the rear system is isolated by solenoids when the key is off but I don't know that and I couldn't figure it out from the shop manual.
I'm okay with bleeding the rear, it needs flushing anyway, but if both front and rear are connected and I have to bleed the entire system, that would be challenging.
Do I need any special tools or skills to replace that dust seal? I'm hoping I can just install a new seal and not mess with anything else. The caliper isn't leaking and from what I can see the piston looks to be in good shape.
Re: the missing insulator and shim: I don't know whether the pads that were installed were Suzuki or after-market. Are there after-market pads that don't require the insulator and shim? Seems unlikely, but it's the one possible explanation (outside of incompetence) I could think of for them not being there.