{"id":18879,"date":"2023-06-13T08:00:00","date_gmt":"2023-06-12T23:00:00","guid":{"rendered":"https:\/\/www.decoboco.info\/en\/?p=18879"},"modified":"2026-09-24T13:46:12","modified_gmt":"2026-09-24T04:46:12","slug":"zephyr550-400-caliper-overhaul-aluminum-piston","status":"publish","type":"post","link":"https:\/\/www.decoboco.info\/en\/20230613\/unclassified\/zephyr550-400-caliper-overhaul-aluminum-piston","title":{"rendered":"ZEPHYR550\/400 Caliper Overhaul. Aluminum Piston Conversion (Partially)"},"content":{"rendered":"
\"\"<\/a><\/div>\n
\"\"<\/figure>\n\n\n\n
<\/div>\n\n\n\n

It’s the rainy season, isn’t it? Damp and drizzly… it’s been raining constantly (\uff1b\u2200\uff1b)

Now, I’m overhauling the original Tokico single-piston caliper and want to convert to aluminum pistons as much as possible! (wishful thinking)


I did various research and it’s partially possible (*\u00b4\u03c9\uff40*)<\/p>\n\n\n\n

<\/div>\n\n\n\n\n\n\n\n
<\/div>\n\n\n\n
\n
\n
\"\"<\/figure>\n<\/div>\n\n\n\n
\n
\"\"<\/figure>\n<\/div>\n<\/div>\n\n\n\n

Zephyr 400\/550 Original Rear 38.08\u03c6\u00d728.40MM (with resin anchor)
*Please note that specifications may vary depending on model year.<\/p>\n\n\n\n

<\/div>\n\n\n\n
\n
\n
\"\"<\/figure>\n<\/div>\n\n\n\n
\n
\"\"<\/figure>\n<\/div>\n<\/div>\n\n\n\n

Zephyr 400\/550 Original Front (Large) 33.83\u03c6\u00d731.16MM (with resin anchor)<\/p>\n\n\n\n

\n
\n
\"\"<\/figure>\n<\/div>\n\n\n\n
\n
\"\"<\/figure>\n<\/div>\n<\/div>\n\n\n\n

Zephyr 400\/550 Original Front (Small) 26.86\u03c6\u00d730.85MM (with resin anchor)<\/p>\n\n\n\n

<\/div>\n\n\n\n

The front (small) can be done with Honda’s resin piston only. The (large) doesn’t exist in that length.
The rear has options available.<\/p>\n\n\n\n

<\/div>\n\n\n\n

Now let me check the rear dimensions by arranging them in images.<\/p>\n\n\n\n

\"\"<\/figure>\n\n\n\n

Kawasaki 43048-0003<\/a><\/h2>\n\n\n\n
<\/div>\n\n\n\n
\n
\n
\"\"<\/figure>\n<\/div>\n\n\n\n
\n
\"\"<\/figure>\n<\/div>\n<\/div>\n\n\n\n
\n
\n
\"\"<\/figure>\n<\/div>\n\n\n\n
\n
\"\"<\/figure>\n<\/div>\n<\/div>\n\n\n\n

The aluminum piston is about 0.9MM longer.
Please note. I’ll use this difference.<\/p>\n\n\n\n

<\/div>\n\n\n\n
\n
\n
\"\"<\/figure>\n<\/div>\n\n\n\n
\n
\"\"<\/figure>\n<\/div>\n<\/div>\n\n\n\n
\n
\n
\"\"<\/figure>\n<\/div>\n\n\n\n
\n
\"\"<\/figure>\n<\/div>\n<\/div>\n\n\n\n

Honda 45107-ML0-016<\/a>

I’ll use this for the front (small).
The resin piston is about 1.3MM longer.
Well, I don’t think anyone would copy this, but here’s a reference.<\/p>\n\n\n\n

<\/div>\n\n\n\n
\n
\n
\"\"<\/figure>\n<\/div>\n\n\n\n
\n
\"\"<\/figure>\n<\/div>\n<\/div>\n\n\n\n

The culmination of pad grease enthusiasts gets stuck through the gaps in the resin anchor.
Often you can’t remove it without heating.

I wish old stuff would be removed and fresh grease applied.<\/p>\n\n\n\n

<\/div>\n\n\n\n


<\/p>\n\n\n\n

\n
\n
\"\"<\/figure>\n<\/div>\n\n\n\n
\n
\"\"<\/figure>\n<\/div>\n<\/div>\n\n\n\n



I’ll proceed with seals for the Zephyr.
Be sure to pass them through the piston for inspection.<\/p>\n\n\n\n

<\/div>\n\n\n\n
\"\"<\/figure>\n\n\n\n
<\/div>\n\n\n\n

The key to a single-piston caliper is making the slide as smooth as possible.
I think it’s better to remove the old grease without adding more, and apply only the minimum amount.<\/p>\n\n\n\n

<\/div>\n\n\n\n
\"\"<\/figure>\n\n\n\n
<\/div>\n\n\n\n

The cylinder inner wall is also clean, and assembly becomes even more enjoyable \u266a<\/p>\n\n\n\n

<\/div>\n\n\n\n
\"\"<\/figure>\n\n\n\n
<\/div>\n\n\n\n

The rear caliper is now converted to aluminum pistons.<\/p>\n\n\n\n

<\/div>\n\n\n\n
\"\"<\/figure>\n\n\n\n
<\/div>\n\n\n\n

I couldn’t find a close match for the front caliper piston (large), so
I decided to use a mix of steel and resin.<\/p>\n\n\n\n

<\/div>\n\n\n\n
\n
\n
\"\"<\/figure>\n<\/div>\n\n\n\n
\n
\"\"<\/figure>\n<\/div>\n<\/div>\n\n\n\n
<\/div>\n\n\n\n

Single-piston calipers can become stiff if the boot condition is poor.
Replacing it along with pad changes makes operation smoother.<\/p>\n\n\n\n

<\/div>\n\n\n\n
\"\"<\/figure>\n\n\n\n
<\/div>\n\n\n\n

The rear bracket shape is so maniacal I had to check the parts list.
Once you see it, it makes sense, but… yeah.<\/p>\n\n\n\n

<\/div>\n\n\n\n
\n
\n
\"\"<\/figure>\n<\/div>\n\n\n\n
\n
\"\"<\/figure>\n<\/div>\n<\/div>\n\n\n\n
<\/div>\n\n\n\n

DuPont Molykote SH-44M Silicone Grease<\/a>
Well, anything works really“The design looks cool”<\/strong>

As expected from DuPont, it has an expiration date (\uff1b\u2200\uff1b)<\/p>\n\n\n\n

<\/div>\n\n\n\n
\"\"<\/figure>\n\n\n\n
<\/div>\n\n\n\n

RK’s sintered pads seem to be discontinued.
There are quite a few discontinued items…

I decided to use Daytona’s Golden Pad X instead.
Front NO056<\/a>
Rear NO058<\/a><\/strong>

I wonder if axial caliper pads will become harder to find in the future.
<\/p>\n\n\n\n

<\/div>\n\n\n\n
\"\"<\/figure>\n\n\n\n
<\/div>\n\n\n\n

I’m sourcing titanium bleeder nipples.<\/a>
They don’t rust, which is nice (*\u00b4\u03c9\uff40*)<\/p>\n\n\n\n

<\/div>\n\n\n\n
\"\"<\/figure>\n\n\n\n
<\/div>\n\n\n\n

For now, front and rear caliper overhaul and pad installation are complete.
I’m torn between replacing or overhauling the brake master (*\u00b4\u03c9\uff40*)

When brake caliper seals deteriorate,
“the push and pull become heavy.”<\/strong>

Brake input is“pressure”<\/strong>
return is“seal deflection”<\/strong>
When seals wear out and harden, return becomes poor and push-pull becomes heavy.

When it goes “suuu~” and you think “Oh! It’s light!” – that’s when you can really enjoy your bike.<\/p>\n\n\n\n

<\/div>\n\n\n\n

(\u00b4\u30fc\uff40) Brake calipers are super important.
Proper maintenance is essential.<\/h2>\n\n\n\n
<\/div>\n\n\n\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\n\t\t\t\t\t\t\"\"\t\t\t\t\t<\/a>\n\t\t\t\t<\/div>\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\n\t\t\t\t\t\tToray SH 44M Silicone Grease 2705290 100g (SH44M100TUBE)\t\t\t\t\t<\/a>\n\t\t\t\t<\/div>\n\n\t\t\t\t\t\t\t\t\t
\u6771\u30ec(TORAY)<\/div>\n\t\t\t\t\n\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\u00a53,939\t\t\t\t\t\t\uff082026\/09\/21 15:35\u6642\u70b9 | Amazon\u8abf\u3079\uff09<\/span>\n\t\t\t\t\t<\/div>\n\t\t\t\t\n\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\n\t\t\t\t\t\t\t\"\"\n\t\t\t\t\t\t\t\u53e3\u30b3\u30df\u3092\u898b\u308b<\/span>\n\t\t\t\t\t\t<\/a>\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\n\t\t\t\t\t\n\t\t\t\t\t\tAmazon\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\n\t\t\t\t\t\n\t\t\t\t\t\tRakuten\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\n\t\t\t\t\t\n\t\t\t\t\t\tYahoo!\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\"\"\n\t\t\t\t\t\u30dd\u30c1\u30c3\u30d7<\/span>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\n\n\n
<\/div>\n\n\n\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\n\t\t\t\t\t\t\"\"\t\t\t\t\t<\/a>\n\t\t\t\t<\/div>\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\n\t\t\t\t\t\tDaytona Motorcycle Brake Pad Golden Pad X (Sintered Metal Pad) Ninja1000SX (20-21) Z1000 (14-21) Zephyr \u03c7 (97-08) and Others Rear 97167 Serial No: 58\t\t\t\t\t<\/a>\n\t\t\t\t<\/div>\n\n\t\t\t\t\t\t\t\t\t
\u30c7\u30a4\u30c8\u30ca(Daytona)<\/div>\n\t\t\t\t\n\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\u00a55,281\t\t\t\t\t\t\uff082026\/09\/21 18:35\u6642\u70b9 | Amazon\u8abf\u3079\uff09<\/span>\n\t\t\t\t\t<\/div>\n\t\t\t\t\n\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\n\t\t\t\t\t\t\t\"\"\n\t\t\t\t\t\t\t\u53e3\u30b3\u30df\u3092\u898b\u308b<\/span>\n\t\t\t\t\t\t<\/a>\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\n\t\t\t\t\t\n\t\t\t\t\t\tAmazon\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\n\t\t\t\t\t\n\t\t\t\t\t\tRakuten\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\n\t\t\t\t\t\n\t\t\t\t\t\tYahoo!\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\"\"\n\t\t\t\t\t\u30dd\u30c1\u30c3\u30d7<\/span>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\n\n\n
<\/div>\n\n\n\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\n\t\t\t\t\t\t\"\"\t\t\t\t\t<\/a>\n\t\t\t\t<\/div>\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\n\t\t\t\t\t\tDaytona Motorcycle Brake Pad Golden Pad X (Sintered Metal Pad) Zephyr 750 (90-06) Zephyr 400 (89-95) and Others 97165 Serial No: 56\t\t\t\t\t<\/a>\n\t\t\t\t<\/div>\n\n\t\t\t\t\t\t\t\t\t
\u30c7\u30a4\u30c8\u30ca(Daytona)<\/div>\n\t\t\t\t\n\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\u00a55,369\t\t\t\t\t\t\uff082026\/09\/21 18:35\u6642\u70b9 | Amazon\u8abf\u3079\uff09<\/span>\n\t\t\t\t\t<\/div>\n\t\t\t\t\n\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\n\t\t\t\t\t\t\t\"\"\n\t\t\t\t\t\t\t\u53e3\u30b3\u30df\u3092\u898b\u308b<\/span>\n\t\t\t\t\t\t<\/a>\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\n\t\t\t\t\t\n\t\t\t\t\t\tAmazon\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\n\t\t\t\t\t\n\t\t\t\t\t\tRakuten\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\n\t\t\t\t\t\n\t\t\t\t\t\tYahoo!\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\"\"\n\t\t\t\t\t\u30dd\u30c1\u30c3\u30d7<\/span>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\n\n\n
<\/div>\n\n\n\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\n\t\t\t\t\t\t\"\"\t\t\t\t\t<\/a>\n\t\t\t\t<\/div>\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\n\t\t\t\t\t\t\u30c1\u30bf\u30f3\u88fd \u30a8\u30a2\u30d6\u30ea\u30fc\u30c9 \u30b9\u30af\u30ea\u30e5\u30fc M7 P1.00 \u30b7\u30eb\u30d0\u30fc \u30a8\u30a2\u30d6\u30ea\u30fc\u30c0\u30fc \u30d0\u30eb\u30d6\t\t\t\t\t<\/a>\n\t\t\t\t<\/div>\n\n\t\t\t\t\t\t\t\t\t
EALE<\/div>\n\t\t\t\t\n\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\u00a5990\t\t\t\t\t\t\uff082023\/06\/12 15:07\u6642\u70b9 | Amazon\u8abf\u3079\uff09<\/span>\n\t\t\t\t\t<\/div>\n\t\t\t\t\n\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\n\t\t\t\t\t\t\t\"\"\n\t\t\t\t\t\t\t\u53e3\u30b3\u30df\u3092\u898b\u308b<\/span>\n\t\t\t\t\t\t<\/a>\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\n\t\t\t\t\t\n\t\t\t\t\t\tAmazon\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\n\t\t\t\t\t\n\t\t\t\t\t\tRakuten\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\n\t\t\t\t\t\n\t\t\t\t\t\tYahoo!\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\"\"\n\t\t\t\t\t\u30dd\u30c1\u30c3\u30d7<\/span>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\n\n\n
<\/div>\n\n\n\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\n\t\t\t\t\t\t\"\"\/\t\t\t\t\t<\/a>\n\t\t\t\t<\/div>\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\n\t\t\t\t\t\tKawasaki OEM 38\u03c6\u00d729MM Aluminum Piston (Caliper) 43048-0003\t\t\t\t\t<\/a>\n\t\t\t\t<\/div>\n\n\t\t\t\t\t\t\t\t\t
\u30ab\u30ef\u30b5\u30ad(Kawasaki)<\/div>\n\t\t\t\t\n\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\u00a55,644\t\t\t\t\t\t\uff082026\/09\/20 13:33\u6642\u70b9 | Amazon\u8abf\u3079\uff09<\/span>\n\t\t\t\t\t<\/div>\n\t\t\t\t\n\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\n\t\t\t\t\t\t\t\"\"\n\t\t\t\t\t\t\t\u53e3\u30b3\u30df\u3092\u898b\u308b<\/span>\n\t\t\t\t\t\t<\/a>\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\n\t\t\t\t\t\n\t\t\t\t\t\tAmazon\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\n\t\t\t\t\t\n\t\t\t\t\t\tRakuten\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\n\t\t\t\t\t\n\t\t\t\t\t\tYahoo!\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\"\"\n\t\t\t\t\t\u30dd\u30c1\u30c3\u30d7<\/span>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t","protected":false},"excerpt":{"rendered":"

It’s the rainy season, isn’t it? Damp and drizzly… it’s been raining constantly (\uff1b\u2200\uff1b) Now, I’m overhauling the original Tokico single-piston caliper and want to convert to aluminum pistons as much as possible! (wishful thinking) I did various research and it’s partially possible (*\u00b4\u03c9\uff40*)<\/p>\n","protected":false},"author":2,"featured_media":18852,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"pochipp_cv_data":"{\"d49c9dc6\":{\"pv\":1109,\"imp\":539,\"clickedOther\":1,\"clickedAmazon\":2,\"clickedRakuten\":1},\"802e2b2e\":{\"pv\":1109,\"imp\":473,\"clickedAmazon\":5,\"clickedOther\":3},\"7ce6bda1\":{\"pv\":1109,\"imp\":414,\"clickedOther\":1,\"clickedRakuten\":1,\"clickedAmazon\":4,\"clickedYahoo\":1},\"4ddcf8e4\":{\"pv\":1109,\"imp\":388,\"clickedAmazon\":12,\"clickedOther\":11,\"clickedRakuten\":5,\"clickedYahoo\":7},\"51ed4f64\":{\"pv\":1109,\"imp\":353,\"clickedAmazon\":2,\"clickedRakuten\":3,\"clickedOther\":6,\"clickedYahoo\":1}}","swell_btn_cv_data":"","footnotes":""},"categories":[4,41],"tags":[279,607,601,623,612],"class_list":["post-18879","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-unclassified","category-zephyr550zr550","tag-caliper-oh","tag-zephyr-400","tag-zephyr-550","tag-zephyr400","tag-zephyr550"],"_links":{"self":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts\/18879","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/comments?post=18879"}],"version-history":[{"count":0,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts\/18879\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/media\/18852"}],"wp:attachment":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/media?parent=18879"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/categories?post=18879"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/tags?post=18879"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}