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Discussion Starter #1
Here's the short of it: Does anyone on the Front Range have a rear caliper and/or re-con parts for an early VEE ('03 (-'12?) DL1000?
12 hours from home (Prescott, AZ) and was planning "the long way" home tomorrow morning.
Luckily, I have my tools, a space in which to work, and access to a car in which to retrieve parts.
I was out for a putt around SE Denver this afternoon and noticed a lot of drag and a hard, poorly responsive rear pedal. Got it stopped, and once it was up on the center stand, I found the rear caliper sticking, super hot and with a dusky, discolored rotor. No smoke, no glow, ::) and no brake lining odor. I could hear the parts "ticking" as they cooled. I let it sit for a few minutes and worked the rear pedal several times and the brake released. Rode cautiously to nearest motorcycle parts house (and a Suzuki dealer) and they don't stock the caliper, seals or piston kit. Looking at Tuesday next week. This is not an option for me, unless it means riding through deer/elk country without a rear brake (which I'm not holding as any kind of option). Currently checking other stores for both OEM and aftermarket parts, and so far, it's not looking so good.
I have P/Ns if helpful;
OEM Caliper assy: 69100-06G00-999
Piston set: 69100-04810
Piston seals: 69100-04820

And here's an aftermarket Piston Set: K&L 32-1336

I have cash and I can come to you.
Mike 72 zero-35 zero- 22 zero 7.
Thanks for replies
 

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I can't help on the parts, but have you pulled the caliper apart and cleaned and greased things up and reassembled. Maybe just dried out or rust on the pistons?
 

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Discussion Starter #3
I can't help on the parts, but have you pulled the caliper apart and cleaned and greased things up and reassembled. Maybe just dried out or rust on the pistons?
Hey Outbackwack thanks for the reply.
Yep, just did that. No rust, but definitely discolored (gold/brass). While I had it apart, I tried to push the piston in by hand to no avail (no channel locks in my kit) (yet), but when I (carefully) depressed the rear brake pedal, I could feel the piston push out very slightly. I put it together and can hear a little friction when I spin the wheel and actuate the lever by hand, but it doesn't stop the wheel like it ought to. Went out for a test spin and although I can hear a hint of it, I have no rear brake to speak of. With piston stuck open I would expect the pedal to be hard, with little travel, but it actually travels quite a bit more than when the brake is working...just no friction.
I did get on the pedal pretty good trying to loosen up the piston.
Wonder if that means I should be looking at master cylinder seals as well?
More thoughts?
 

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How far does the pedal depress? If it pushes easily but no brake compression have you tried a full brake bleed? If the pedal is hard to depress the master and/or slave cylinder may be clogged and need cleaning/rebuild. Try a c-clamp on the pistons to compress them and maybe it will "blow back" any crud up into the master/slave cylinders for cleaning? Or are the pistons already compressed and not pushing out on the pads? If compressed and not pushing the pads I'd think holes are plugged in the master/slave cylinder. Good luck.
 

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Discussion Starter #5
I pulled everything apart cleaned, lubed and flushed the system with fresh fluid... I thought for sure I had fried the seals and probably scored the piston pretty badly. This was a good lesson on how important clean, fresh brake fluid is.
Although I got a late start yesterday, everything is working like it ought to.
Will post pics of the ride when I get home.
Thanks again.
 

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Riding without the rear brake isn't preferred but can be done.
Ran across a feller who had serviced his rear brake the day before and it had now seized up glowing red. I had tools so we waited for to cool and took the caliper loose and tie wrapped it off to the side.
Then we finished the ride, no harm no foul.
Friend hit a rock and bent his front rim and he undid the right front caliper and tie wrapped it out of the way to ride home.
Not ideal but not a reason to call a tow truck either....if you are practical person.

Like the time my transmission on my BMW blew up the 5th gear bearing. I left it in 4th and rode the 150 miles home.
It's not exactly like coming back into the atmosphere with the wing tiles missing.
 
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