Brake caliper rebuild
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Joined: Jul 2011
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From: Western Pennsylvania
Brake caliper rebuild
Been having problems with the pistons freezing up in my 2008 EG brake caliper.Thought I would try a rebuild kit. Called the local dealer. Not available though HD. Does anyone make a rebuild kit,or do the caliper seals and o-rings never go bad.
Road Master
Joined: Jun 2009
Posts: 932
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From: CENTRAL IL
j and p cycles list several kits that appear to fit, you might want to recheck with another dealer. also if you check the pistons on the calipers I suspect you will find a ridge of reake dust build up the is keeping them from retracting, sometimes you can clean the ridge off and not have to rebuild the caliper if the kit does turn out to be unavailable
Last edited by SIDECAR BOB; Jul 14, 2014 at 02:29 PM.
Elite HDF Member
Joined: Sep 2007
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From: Near Myrtle Beach, SC
Agree with Sidecar Bob, your pistons are likely just dirty.
Get yourself some spray brake cleaner, remove calipers from the bike, then get yourself a piece of wood (or plastic) about 1/4" thick. Place the piece of wood in the caliper between the brake pads.
Apply very gentle pressure to the brake lever to pump the cylinders out just until the pads touch the piece of wood. You will probably find that one side will pump out before the other. Once both sides are touching the wood, then spray and clean the heck out of the pistons with the spray brake cleaner. Wet them down good then use an old toothbrush for removing stubborn grime and accessing the hard to reach areas.
After finishing, use the wood to help push the pistons back into a retracted position. Warning: Do not compress the brake lever until you have the wood in place. If you do, you are likely to blow out and/or over-extend the pistons and then you have a whole new set of problems.
Get yourself some spray brake cleaner, remove calipers from the bike, then get yourself a piece of wood (or plastic) about 1/4" thick. Place the piece of wood in the caliper between the brake pads.
Apply very gentle pressure to the brake lever to pump the cylinders out just until the pads touch the piece of wood. You will probably find that one side will pump out before the other. Once both sides are touching the wood, then spray and clean the heck out of the pistons with the spray brake cleaner. Wet them down good then use an old toothbrush for removing stubborn grime and accessing the hard to reach areas.
After finishing, use the wood to help push the pistons back into a retracted position. Warning: Do not compress the brake lever until you have the wood in place. If you do, you are likely to blow out and/or over-extend the pistons and then you have a whole new set of problems.
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Joined: Jul 2011
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From: Western Pennsylvania
Thanks Guys, I did tear down the Calipers and popped out all 4 pistons. I cleaned up everything and polished the pistons with 000 steel wool. The outer pistons slide right in with no resistance. The inner side for some reason are hanging up about half way in but will go in with moderate force.Even after completely cleaned. I think I'm gonna try JP cycle and order a rebuild kit. Thanks for the help.
Road Master
Joined: May 2008
Posts: 1,178
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From: Central Calif
hmmm -- I bought a rebuild kit for a 2000 EG dealer had to order from Harley but it was readily available. - came with 4 pucks and all the gaskets -
when cleaning your pucks/pistons - use as fine of grit of paper as possible -- 000 is way to rough for my taste.
when cleaning your pucks/pistons - use as fine of grit of paper as possible -- 000 is way to rough for my taste.
Last edited by OwnerOfHarriet; Jul 15, 2014 at 10:03 AM.
Club Member
Joined: Jun 2007
Posts: 45,429
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From: Bedford UK
Your bike has the previous generation of calipers, OP's has Brembos, from what I can make out. That doesn't excuse HD for not making kits available!
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