I am sooo pissed off with myself at the moment and I am after some sound advice before I throw 'something' at something...
I decided to change my front brake pads today on the bike (with ABS) and do a service on my calipers. After removing the old pads and before installing the new ones, I noticed that some of the pistons were not moving easily (some were gummed up with brake dust and other crap).
I used some brake cleaner to spray the inside of the calipers and I gave them a little pump to extend the pistons. I then cleaned some more, pushed them back in with two small G clamps (all i had - plus a rag to prevent scratching of the outside of the caliper) and after doing this a few times, I decided (wrongly in hind sight) that i'd clamp the pistons that move easily... so the stuck ones would push out gently.
After stuffing around with the G clamps being careful to evenly move the pistons in, I didn't notice one of the other pistons was almost fully extended (Rag was in the way)... so I gave the brake lever a little pump and POP.... then gush!!!
After a few verbal exchanges with myself, I did get the piston back in without too much trouble but here in lies my question:
My Clymer manual says that 'the 2008/09 stock
Brembo caliper assembly cannot be disassembled for service' - I didn't see any rubber seals or orings as such and I am guessing that the piston is a pretty tight fit.... Does this mean that i need to buy a new one?
Note: I did not split the caliper, I just eased the piston back in carefully with the two G clamps. Also, I don't have any fluid yet to flush the system or check for leaks.
Because this bike is fitted with ABS and I know that a flush 'will require or should have' the Harley computer connected to reset any ABS codes. Should I just upgrade the calipers with a brand that is better than stock (for a reasonable price)
and get it all fixed at the dealer?
Is there any recommendations for a reliable brand that doesn't require new disks or mounting hardware?
Does the six piston calipers operate differently to the four - really?
I need to get my bike back on the road in the next few days or I am screwed for transport to work!
Any advice is appreciated.