[jjmaine]

Nice bike and sweet set-up! This past summer I had to replace my chain as well at 10,000 miles. The chain was actually in fine shape but the last time I was cleaning it a couple of the o-rings fell off so I replaced it.
How do you like the Ohlins cartridges in your forks. I have the same as you with the 7.5 n/m springs to install this winter.

 

[jjmaine]

Sweet! I've got all the stuff to rebuild my Tokico and rear oem caliper, new pads and the SV bracket. Just got to find time. The bracket/caliper aligned perfect with your rotor? I think some have had to file and adjust but I think they were using the Cbr600 Nissan caliper...
I've done some rough math on what I will have spent this winter on my 300 and it should end up somewhere around $2k 😕 Not that I care since last winter I spent much more on Crf230f w/ big bore, performance cam and all new top end as well as making it a street legal supermoto. Oh and it's still slow as a turd! But I had fun and learned a lot doing it which is why I do it. The Crf230f is the Ninja 250/300 of the dirtbike world. Everyone that actually owns one loves it and everyone who doesn't says it's a girls bike. I guess I just love girls bikes then.

 

[jjmaine]

Yeah yours was the post I read that you had to file it. I have a theory that that might be why SV Racing took the Nissan calipers off their list since they might require slight fiddling where the Tokico are true bolt on. Could be wrong and I never asked him since I got an ‘03 Gsxr600 caliper, same caliper as the OP.

 

[jjmaine]

Hey Jimmy, did your All Balls kit come with the correct brake pad pin? Mine is too large. Also, did you notice that the larger pistons were significantly harder to push in past the seals than the smaller pistons?
Wondering if they sent me the wrong kit though it says it is for an ‘03 gsxr600…

 

[jjmaine]

Awesome thanks! Mine came with 2 pins as well but you can see that they are too big around and don’t have a spot for the clip like oem. I dont care about the clip but want new pins lol.
I’m guessing they just put the wrong pins in this kit, strange enough the pins they sent me in the Gsxr600 kit are the same as what comes in the kit for the Ninja 300 rear caliper part 13-3001…
I’ll check on the All Balls website, they usually list each individual part number and quantity in each kit.

 

[jjmaine]

When you get a chance, is there any way you can check your remaining seal part numbers and see if they match mine? From looking on All Balls site, the picture of your SV1000 kit shows the correct pins and their picture of my Gsxr600 kit shows the pins they gave me in the picture, which are the wrong ones. Alledgedly, all years SV1000 front calipers are the exact same as the ‘01-‘03 Gsxr600’s. It just makes me wonder why they sell two separate kits for the same caliper? Who knows but if my seals are correct I’ll get them to replace my pins and call it good. What worries me is my parge pistons were very tough to install and took a lot of force to push home. On every other caliper I’ve rebuilt, once you get the piston past both seals, it snaps easily to the bottom.
I did compare them to the old seals and they looked the same to my eye, maybe a but thicker since they are new…

 

[jjmaine]

No worries, it’s not a big deal. Merry Christmas!

 

[jjmaine]

How do those 1" handlebar risers feel? I'm in the same boat as you with the Ohlins fork cartridges. I suspect that is why you installed the risers to make room for the Ohlins caps? I'm thinking about ordering a set of risers and having them milled down to 7mm to raise the handlebars as little as possible but to still make room for the fork caps. Clip-ons are out of the question, I tried a set of Woodcraft clip-ons and they felt bad to me...

 

[jjmaine]

Okay thanks so I doubt an extra 7mm will be too noticeable. I like the handlebars just fine as stock since I'm used to them. Either I'll have to add risers or try to get the handlebars themselves milled out....

 

[jjmaine]

Hey Jimmy, any chance you might be able to check the part numbers on your spare seals to see if mine are the same? I emailed All Balls and they never responded. If my seals are correct I don't mind using my old brake pad pin but if the entire kit is wrong I want them to send me the right kit so I can use the correct seals. Like I said before the seals on the larger pistons were super tight. I've never had such a hard time pushing the pistons back in after a rebuild...

 

[jjmaine]

Excellent thank you! I’ve emailed All Balls twice now explaining that their rebuild kit for the 2003 Gsxr600 calipers was wrong and to ask if both kits used the same seals. At the very least it came with the wrong brake pad pins.
I figure if they were the same and you used them they will work fine for me. Just never had such a time getting pistons back in.
Same seals in both kits so I’m good to go thanks! I won’t buy anymore All Balls kits. I never even asked to return anything or for a refund. I just wanted them to confirm I was using the correct seals.

 

[jjmaine]

Wow, crazy how just new bolts and the entire caliper looks fresh now! Have you had a chance to ride much with the new setup? Not sure where in the US you love but here today it is -14 and feels like -40 with windchill…

 

[jjmaine]

Pretty much the same thing I did. I did test the caliper after assembly by putting a piece of wood between the pistons and using compressed air to push them out. They all worked smoothly but the larger pistons need a bit more psi to extend them fully.
I wouldn’t have been too worried except I don’t want to ruin my new pads and rotor with pistons that won’t retract correctly because the seals are too tight. I’ll make damn sure they are before I ride it. I’m sure after some good use they’ll loosen up a bit as well.
The pistons in my caliper are aluminum and cleaned up to look like new…. I guess they went lightweight for the Gsxr600 vs the Sv1000?