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Author Topic: Rebuilding the HD OE Brembo Calipers  (Read 2800 times)

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Twolanerider

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Rebuilding the HD OE Brembo Calipers
« on: July 10, 2010, 12:50:59 PM »

Had some of the brethren ask for illustration of these calipers apart when the rebuild-ability of these calipers came up in this old thread:

http://www.cvoharley.com/smf/index.php?topic=48985.0

At that time the calipers and other parts had already gone off to Chrome Masters.  Got a nice box back yesterday though.  Motor mount top and front brackets, axles, multiples sets of handlebar controls, lots of brakes; it was like freaking Christmas!!

Spent a couple hours this morning doing a final cleaning on then reassembling all the calipers.  Only one set of Brembo calipers in this mix; but here they come. 

I love Christmas in chrome; and this was only one box full :huepfenjump3: :drink: !!
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Twolanerider

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Re: Rebuilding the HD OE Brembo Calipers
« Reply #1 on: July 10, 2010, 12:56:40 PM »

If anyone wants to get their black or silver 08 and up Brembo calipers chromed don't let the "can't be rebuilt" dictate from Mother Harley worry you a great deal.  They are actually quite easy to disassemble and reassemble.  Bores are all the same width and depth so pistons are all the same.  Nothing to mix up inside.  Three bolts and a pad pin come out to separate the halves.

Perhaps the most important qualifier is don't lose any of the internal parts.  Harley nor anyone else sells them.  Lose even the smallest o-ring and you're out hundreds of bucks for a caliper.

Each bore has two o-rings.  Dramatically different in thickness and width.  You can't mix them up.

This pic doesn't show well where they go (poor light).  But you'll get the idea.
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Twolanerider

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Re: Rebuilding the HD OE Brembo Calipers
« Reply #2 on: July 10, 2010, 12:58:31 PM »

Here are the rings themselves.  Significantly different from each other.  Obvious both where and how they go in.  The narrower ring has a specific inner surface.  But it won't twist 180 degrees without actually twisting.  So, again, you really can't get it wrong.

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Twolanerider

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Re: Rebuilding the HD OE Brembo Calipers
« Reply #3 on: July 10, 2010, 01:00:22 PM »

All the internals of a single caliper are comprised of; not much.  Four pistons, eight o-rings and one seal that seals the fluid transfer point between the two halves of the caliper. 

The other loose parts you'll keep track of are just for brake pad retention and placement.  Harley actually sells those so if you lose them you're not totally screwed.
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Twolanerider

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Re: Rebuilding the HD OE Brembo Calipers
« Reply #4 on: July 10, 2010, 01:02:07 PM »

Here's an attempt at illustration of the seal between the two halves.  One half has the inset seen to the picture-left side of this caliper.  The "nipple" part of the seal inserts in it.  The seal in this picture is simply setting on the surface of the caliper next to the hole it will install to.
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Twolanerider

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Re: Rebuilding the HD OE Brembo Calipers
« Reply #5 on: July 10, 2010, 01:03:08 PM »

And there it is installed (i.e., just pushed in the hole).  The face of the other caliper half will seal against in when the two halves bolt together.
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Twolanerider

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Re: Rebuilding the HD OE Brembo Calipers
« Reply #6 on: July 10, 2010, 01:06:05 PM »

Once the o-rings are in the bores the pistons install by hand.  I wipe them down with a clean rag and a very light coat of a spray lube of some kind.  Wipe it back off to leave only the lightest of coats behind.  Just enough to assist the pistons sliding by the o-rings.

The pistons are then lined up and pushed in with your fingers.  Doesn't take much pressure at all when they're lined up correctly.
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Twolanerider

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Re: Rebuilding the HD OE Brembo Calipers
« Reply #7 on: July 10, 2010, 01:12:19 PM »

Then, voila, to halves all done.  I've not looked but was told the Brembo chrome kit from HD was over $800.  If so this was much cheaper.

Spent a couple weeks waiting for a good deal on cores on eBay.  Got a pair for $135.  Chroming was about $80 per caliper.  So less than $250 in to a pair of Brembo chrome calipers.

Also had a full handlebar control set (master cylinder, clamps, clutch perch, etc) that came off eBay for $25.  Chroming all those bits was about $100.  So for less than $400 you can collect almost everything needed to do a Brembo front brake conversion on your pre-08 touring bike. 

Only other expenses will be some chrome bolts if you want them (got everything except the pad pin at Ace Hardware for $20.00).  If you're chroming your existing black or silver parts you're not even out the core charges.

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Twolanerider

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Re: Rebuilding the HD OE Brembo Calipers
« Reply #8 on: July 10, 2010, 01:17:03 PM »

Oh yeah, these are the front brakes for the ongoing SERK project.  One rear from the parts pictured is also for that project.  One rear for the 05 and a pair of non-Brembo fronts for the SEEG.  Then they'll all have chrome brakes all the way around.

SEEG gets the chrome rear axle too.  Then its axle will get chromed for the SERK.  The motor mount brackets (just thinking out loud here to mentally inventory the pictures I'm looking at) go to the SERK.  The extra complete sets of Brembo handlebar controls/master cylinder will go to eBay along with the rest of the spares.  The spares will almost pay for the chrome work on everything.  So final cost to gain the brakes for the SERK and the other bits will be just the few core expenses.  God it's fun being cheap!
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Twolanerider

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Re: Rebuilding the HD OE Brembo Calipers
« Reply #9 on: July 10, 2010, 03:46:24 PM »

You all are chrome whores (not that this is a bad thing)!

Phone rang about a half hour after the other pics went up.  "What about the pad pin?!"   :huepfenlol2:

Ok....  sure, the pad pin (funky bolt) isn't something you'd ever buy at hardware store that happens to have some chrome hardware.  The local Ace Hardware did have metric hardware to do the rest of it though.  However......

The pin that holds the pads in place can't be seen once the chain link fence is back is installed back on top of the caliper.  It is well hidden.  Even as much of a chrome slut as I am I'm not paying Harley $35 extra for a caliper bolt kit just to get a bolt I'll never see.  The pad pin is behind the cover in this pic.  I did, however, make the head of the pin red so it would blend in (just in case) 8) .
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Re: Rebuilding the HD OE Brembo Calipers
« Reply #10 on: September 27, 2010, 07:52:22 PM »

Rebuild kits for the 08+ Brembo calipers are now availible through the aftermarket, anybody need them let me know.....

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Re: Rebuilding the HD OE Brembo Calipers
« Reply #11 on: December 23, 2010, 10:12:15 PM »

Rebuild kits for the 08+ Brembo calipers are now availible through the aftermarket, anybody need them let me know.....

Jim:

I sent you a PM concerning this info, and have not received a reply.

Thanks,

 :confused5:
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