Go Back   Harley Davidson Forums > Harley Davidson Motorcycles > Touring Models
Sign in using an external account
Register Forgot Password?
Search


Touring Models Road King, Road King Custom, Road King Classic, Road Glide, Street Glide, Electra Glide, Electra Glide Classic, and Electra Glide Ultra Classic bikes.
Sponsored by: Fuel Moto USA

Welcome to HDForums.com!

Reply
 
 
 
P
 
Thread Tools Search this Thread
  #1  
Old 01-16-2011, 08:19 PM
straightleg's Avatar
straightleg straightleg is offline
One Of The Regulars
Join Date: Dec 2010
Location: Ohio
Posts: 208
Default Brake caliper rebuild + photos

Did this job a year ago


2000 Road King. 15,000 miles. No lever when I got bike. Lever went almost all the way to handle.

Low miles so I took them off, tore them completely apart. Everything cleaned up good. Reused all parts except new bleeder screw and new banjo washers.

Have not bleed brakes yet. Took pictures of tear down and install.

Click the image to open in full size.

Caliper apart - pistons were frozen - pretty dirty
Click the image to open in full size.

Lower half is in middle it has the 2 rubber washers that are off.
Upper half to the right has the part that is the anti rattle metal piece. I believe the pad top metal parts slide across it when cleaned and greased.
Click the image to open in full size.

Soaking parts in brake cleaner.
They are in my high tech empty butter tub / parts cleaner thingy

Click the image to open in full size.


Pistons out. Partially cleaned . Wiper part and rubber oil ring were not taken out of where the piston is installed
Click the image to open in full size.


Inside of piston. Crudy oil/grease in bottom. Holes the have a little hole in them is where those little rubber washers are installed. The brake fluid goes through there and push's piston out.
Click the image to open in full size.


This is what I used to coat the inside of the pistons holes. Outside of the pistons. The pins that hold the brakes. The metal anti rattle metal piece
Click the image to open in full size.


Parts all cleaned and ready to be put back together
Click the image to open in full size.


Greased up piston hole and outside of pistons, and wiper and rubber seal in side of hole
Click the image to open in full size.


After install and wiped surface clean - rubber o rings installed
Click the image to open in full size.


Greased up metal retainer / anti rattle piece
Click the image to open in full size.


Greased up pins for pads
Click the image to open in full size.



Finished install ready to go back on rotor.
Click the image to open in full size.



I hope this helps anyone doing this. My first Harley and my first time doing the brakes. I read my service manual.

I have done a bunch of car brakes before so I understand what the parts do. The service manual does not say lube the metal anti rattle piece or the pins.
I do this when I do car brakes so I did it on the bike.



Straightleg
__________________

First Harley 2000 Road King
Stage one, Thunderheader 2-1

Last edited by straightleg; 01-04-2012 at 07:32 PM..
Reply With Quote
  #2  
Old 01-16-2011, 09:00 PM
hover's Avatar
hover hover is offline
Road Captain
Join Date: Aug 2008
Location: Alberta Canada
Posts: 511
Default

Good write up, I gotta do this soon. Thanks.
__________________
2009 Ultra Classic, 96CI, V&H True Duals, Monster Ovals, S.E air cleaner, S.E 255 cams, S.E compensator, Power Vision from Fuel Moto.
Reply With Quote
  #3  
Old 01-16-2011, 09:14 PM
RIPSAW's Avatar
RIPSAW RIPSAW is online now
Extreme HDF Member
Join Date: Mar 2010
Location: Bates Motel, Fairville U.S.A.
Posts: 12,534
Default

Nice, great pictures. Thanks
__________________

LOUD EXHAUST DOES NOT KEEP NORMAN FROM POPPING YOU .. .. YOU NEED TO WATCH OUT FOR HIM. LOVE MOM
Reply With Quote
  #4  
Old 01-16-2011, 10:04 PM
Harleypingman's Avatar
Harleypingman Harleypingman is offline
Extreme HDF Member
Join Date: Apr 2006
Location: Roswell, GA
Posts: 10,378
Default

Nice pictures. How'd you get the pistons out of the calipers? When I did mine I used the compressed air technique and was shocked at the velocity of the pistons exiting the bores--luckily, no one was hurt.

Carl
__________________

CMA, Crossties Chapter (GA)
IBA 26580
'04 FLHTPX
Reply With Quote
  #5  
Old 01-16-2011, 11:33 PM
straightleg's Avatar
straightleg straightleg is offline
One Of The Regulars
Join Date: Dec 2010
Location: Ohio
Posts: 208
Default

I first took a 1/2 inch piece of oak and sliped it between pistons. I have around 90lbs of air on the compresser.
I have a air sprayer for getting rid of saw dust on something.

I had to spray knock one out. Start over shim wood against the one loose. Spray knock one loose.

Shim wood against that one.
Take it back apart, spray more brake cleaner on it.

Start over.

It took awhile to get all the pistons broke loose.

I did not have the harley tool for this.
Used what I had in the shop. I am a woodworker.

When one broke loose, I reinstalled in to hold the air and shimmed it with wood , so it would not move and break another loose. I did this over and over to get them all loose.

I have more time than money.




Straightleg
__________________

First Harley 2000 Road King
Stage one, Thunderheader 2-1

Last edited by straightleg; 01-16-2011 at 11:38 PM..
Reply With Quote
  #6  
Old 01-17-2011, 12:39 AM
Potato_Potato's Avatar
Potato_Potato Potato_Potato is offline
Outstanding HDF Member
Join Date: Sep 2005
Location: Minnesota
Posts: 2,566
Default

Excellent picts - I have changed pads but have never rebuilt the calipers. Are you sure sure the Service manual says not to lube the pins? I always do with antisieze. It seems to me, however that lubing the pistons and bores would attract brake dust and dirt.
__________________


2008 StreetGlide - Stage 1, Bub 7 True Duals, SERT, Corbin Classic Solo, SE Compensator

☮☮☮☮☮☮☮
Reply With Quote
  #7  
Old 01-17-2011, 07:41 AM
straightleg's Avatar
straightleg straightleg is offline
One Of The Regulars
Join Date: Dec 2010
Location: Ohio
Posts: 208
Default

I have always done it on my car brakes. They even give you a tube of grease.
Mechanics on cars have told me that is the right way to grease all the metal hardware and the pins so everything slides.


Bike
The pistons are a tight fit. Dont see much dirt getting inside.The mechanics manual says to lube pistons on the outside and in the hole.
To use silicone grease from GE

It does not say to lube things outside like the metal piece and pins.

I just used what I use on my cars.



Straightleg
__________________

First Harley 2000 Road King
Stage one, Thunderheader 2-1
Reply With Quote
  #8  
Old 01-17-2011, 07:58 AM
CLL375 CLL375 is offline
Road Captain
Join Date: Jun 2006
Location: Houston, TX
Posts: 544
Default

Nice write up but never spray brake cleaners on calipers that still have the rubber seals in them and you should have used the brake fluid to lube the piston holes. I see you left the pistons in when you used the brake cleaner but you still risk the chance of damaging the seals.
__________________
http://hdforums.com/forum/image.php?type=sigpic&userid=13751&dateline=124329  7275
Vivid Black 07 Night Train
Vivid Black 09 Street Glide
Reply With Quote
  #9  
Old 01-17-2011, 08:20 AM
dawg's Avatar
dawg dawg is offline
Club Member
Join Date: Jun 2006
Location: Vermont
Posts: 20,079
Default

HERE is the instruction sheet for the $13.25 seal kit to rebuild all the calipers.
__________________
'08 105th anniversary Ultra
http://www.vtroaddawgsmc.org/
Reply With Quote
  #10  
Old 01-17-2011, 08:33 AM
straightleg's Avatar
straightleg straightleg is offline
One Of The Regulars
Join Date: Dec 2010
Location: Ohio
Posts: 208
Default

Dawg

I cleaned it all and did not replace the parts. I did grease the parts just like the manual says. Did not use that GE part number or use the HD piston remover.

I also greased the metal part and pins.

Maybe for that price I should have put new parts in. Can always do a redo.



Straightleg
__________________

First Harley 2000 Road King
Stage one, Thunderheader 2-1
Reply With Quote
Old 01-17-2011, 08:33 AM
 
 
 
P
Reply

Tags
anti, banana, brake, caliper, calipers, davidson, harley, install, kit, lube, photos, picture, rattle, rebuild, stay


Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off

Forum Jump

Advertising
Featured Sponsors
Vendor Directory
Sponsors

All times are GMT -5. The time now is 06:54 PM.


Internet Brands, Inc.



Search Engine Optimization by vBSEO 3.6.1