Problem: 2009 Road King Classic brembo caliper service - Harley Davidson Forums: Harley Davidson Motorcycle Forum
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Old 11-05-2012, 12:40 AM   #1 (permalink)
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Unhappy Problem: 2009 Road King Classic brembo caliper service

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.
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Old 11-05-2012, 01:09 AM   #2 (permalink)
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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.
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Old 11-05-2012, 11:28 AM   #3 (permalink)
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Thank you mrmetal for your response... I guess i'll have to shop around for a decent priced set.
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Old 11-05-2012, 01:02 PM   #4 (permalink)
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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.
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Old 11-05-2012, 01:05 PM   #5 (permalink)
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one way i installed a piston & rist pin was to freeze one part & heat the other part .
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Old 11-05-2012, 01:07 PM   #6 (permalink)
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check with p/m to see what p/n calipers yu need then go on e-bay. you can save some $$.
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Old 11-05-2012, 10:14 PM   #7 (permalink)
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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!
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Old 11-06-2012, 05:48 AM   #8 (permalink)
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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.
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