Problem: 2009 Road King Classic brembo caliper service

[Aussie Ads]

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.

[mrmetal]

Performance machine makes good brake parts that you would be looking at 500 bucks for their calipers.

There should be a seal in there toward the back of the piston inside the caliper housing.

The reason that they say they cannot be rebuilt is for liability purposes.

[Aussie Ads]

Thank you mrmetal for your response... I guess i'll have to shop around for a decent priced set.

[eagle1]

caliper manu.'s say never use brake-clean etc. becauseit dryes out the seals. they say soap provides enough lubricant they need.now i'll continue reading your post.

[eagle1]

one way i installed a piston & rist pin was to freeze one part & heat the other part .

[eagle1]

check with p/m to see what p/n calipers yu need then go on e-bay. you can save some $$.

[Aussie Ads]

Thanks Eagle 1, I got a set of chromed Brembo calipers and chrome polished rotors for$305 total... off e-bay (local indy company that has had great reviews). It beats the $860.00 the stealer wants for the same item.... i'll post pictures once done!

[dougtech]

They do not recommend rebuilding calipers because if you split them resealing the machined surfaces to prevent leaks can be a problem. I used to go through this with old Corvette calipers back in the day.