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CVO Technical => Wheels/Tires/Suspension/Brakes => Topic started by: Twolanerider on June 28, 2012, 12:03:21 AM

Title: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on June 28, 2012, 12:03:21 AM
This is a simple enough chore it probably doesn't warrant the next several pictures.  But since it came up the first time a couple years or more ago have occasionally had someone find the old thread(s) and again question if the non-rebuildable Brembo calipers can actually be rebuilt.  Finally remember to take pics while doing a set tonight.  So here goes:

Yes, they are rebuildable.  The non-rebuildable verdict from Mother Harley is company policy but no more.  There's nothing special about rebuilding these calipers compared to others.  It's a simple chore if you're willing.

This pic is a complete seal kit.  The cylinders each take two o-rings (one narrower than the other).  There's also a small o-ring that seals the fluid port that goes between the two halves of the caliper.  Only other part for a complete rebuild is the pistons themselves.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on June 28, 2012, 12:05:26 AM
If you've got the calipers apart because you've sent the parts off to chrome be sure and run a tap through the threaded holes.  They might or might not need it.  But the odds are they will.  Ruining a freshing chromed bolt or caliper half is a bad way to wreck an otherwise quick little project.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on June 28, 2012, 12:06:38 AM
Crappy lighting and a cell phone photo.  So you can't see the two channels in the cylinder.  But they're there.  Thicker and thinner o-ring in each cylinder.  It's obvious when you see it in person.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on June 28, 2012, 12:08:51 AM
With the o-rings in the cylinders wipe them and the pistons with a light coat of clean of brake fluid.  To lubricate for installation of the pistons.  With light pressure find where the pistons feel straight and with light pressure will pop/slide in to the cylinders.  If you have to push very hard it's not lined up straight.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on June 28, 2012, 12:10:25 AM
Note the hole with the arrow pointed toward it.  That's the channel that carries fluid from one caliper half to the other.  The small o-ring in the kit goes in that hole.  Be careful not to drop it as you put the two halves together.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on June 28, 2012, 12:12:05 AM
Becasue it's just an o-ring that's supplied in the kit the little bugger can fall out.  The stock piece is actually a little different.  It's a ring seal with a nipple the extends down in to the hole a bit.  Both will work.  Don't sweat the little stuff.  Just make sure whatever you use doesn't fall out.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on June 28, 2012, 12:14:26 AM
With the two halves together but not fully pulled too each other is when I prefer to install the spring clip that goes over the brake pads.  It just snaps in place.  There is a bow at one end.  That goes over where the brake pad pin bolts through.  Install the spring clip then finish tightening the three bolts that put the caliper halves together.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on June 28, 2012, 12:15:48 AM
Brake pad pin goes in the (obviously) only other hole available after the three bolts that actually hold the halves together are in place.  Once the pads are in place the pin will install and tighten.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on June 28, 2012, 12:17:03 AM
There is a small spring steel clip that slides over a notch in the brake pad pin.  Push it on once the pin is installed through the pads and tightened up.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on June 28, 2012, 12:19:38 AM
After all that is done (less than a half hour) snap the screens on the top and screw in a brake bleeder.  Voila, rebuilt calipers.  Harley's edicts notwithstanding.  Whether because you've sent cores off to chrome or just needed to service it's a very do-able little chore.

Note in the pic here that only four bolts are exposed outside the grill.  One bolt and the pad pin are always hidden.  Since a chrome shop might charge $3-4 per bolt that means only the four exposed bolts really need to go to chrome if you're dressing up a set of calipers.

The rebuild kits are aftermarket (thanks to HD-Dude for first finding these awhile back).  At first there were just complete rebuild kits with pistons and seals.  About $40 per caliper and Drag # 1702-0117 ($33 at Lake Shore) for the front.  A bit more expensive and Drag # 1702-0118 for the rear.  If the pistons are good there's now also a kit that's just the seals.  $12 each and 1702-0125 or 1702-0126 for front and rear respectively.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on June 28, 2012, 12:27:10 AM
If you're doing this for a bike that's new enough to originally have had Brembo calipers that's all you have to do.  If you're intent is to retrofit a pre-Brembo bike as an upgrade there is one more thing necessary.

Note the arrows.  The caliper on the left has a tab still standing next to where the brake line would attach.  On the left caliper (as installed on the bike) that stand is in the way of attaching the brake line on the older bikes.  So Dremel the darn thing off.  After that the calipers bolt directly on a pre-Brembo bike and the stock lines attach.  Find a set of 11.8 brake rotors and you've everything needed at the wheels to make the upgrade to larger/better brakes.

You may or may not choose to change the master cylinder to use the newer cylinder that is spec'd with the Brembo calipers.  I've seen it done both ways.  I prefer using the new cylinder with the newer calipers.  I prefer the feel and feedback at the brake lever with that combination.  But have seen it done with the original master cylinder and it worked ok.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on June 28, 2012, 12:28:11 AM
All done.  Goin' to bed.  Lots of detail for a simple chore.  Hopefully will help someone someday. 

Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: North Georgia Hawg on June 28, 2012, 01:27:06 AM
EXCELLENT POST! THANKS for this hard-to-find info!

No help here from the Mother Ship, that's for sure. The MoCo struck a deal with Brembo to NOT make the rebuild parts even available, so they could make more money off of us by selling only complete Brembo replacement units.

That is what I call "thinly-veiled CONTEMPT for the customer". Glad that others are stepping up and this is changing...
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Gettinold on June 28, 2012, 05:04:33 AM
Thx Don! :2vrolijk_21:
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on June 28, 2012, 07:20:35 AM
Thx Don! :2vrolijk_21:

Very welcome.  Was asked in a PM about the mounting bolts.  If changing to Brembos on a pre-Brembo bike you'll need four 10mm bolts that are 40mm long for the bolts to mount the calipers to the legs.  I use bolts and washers there so the bolts don't dig in to the legs.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Boatman on June 28, 2012, 07:45:44 AM
Don-

Are these pistons perfectly smooth on the OD??   My pistons have small grooves in the OD.  The small grooves go with the movement of the pistons.   I don't know if they are made that way or scored.  Kind of like a rifling effect (for lack of better words).

Thanks-Bob    and for the write up also.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on June 28, 2012, 10:03:46 AM
These are smooth Bob.  Also, none of the dozen or so of the Brembo calipers I've taken apart have had pistons like you describe.  All smooth.  Sealing and moving against o-rings they'd need to be.  Should have no texture at all.  You might be up for kits.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on June 29, 2012, 08:54:43 PM
Was asked in a PM where the colored bleeders and banjo bolts came from and if they were painted.  Not painted, anodized.  Available in a few different colors from:

http://www.2wheelpros.com/lightech-single-banjo-bolt-with-bleeder-1-0-thread-aftermarket-brembo-2356669.html
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Fireguy on June 30, 2012, 08:42:06 AM
How about a pic by pic of you bleeding the brakes. Would like to do this to mine but bleeding the brakes is the only thing stopping me.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on June 30, 2012, 10:23:58 AM
How about a pic by pic of you bleeding the brakes. Would like to do this to mine but bleeding the brakes is the only thing stopping me.

Not that much digital imagery in the world......


No kidding that can be an annoying chore sometimes.  On a non-ABS bike it's straightforward.  But it can still suck.  I fill the master cylinder, hook a vacuum tool up with lines to both front calipers, pull enough vacuum to get fluid out of the cylinder and then stand over the master cylinder and keep adding fluid as it gets low four or five times.  Crack the vacuum at that point then start actually bleeding the calipers.

Five or six pumps and crack a bleeder.  Repeat repeat repeat ad nauseum until you get good brakes.  Might take 20 minutes overall or might take an hour and a half.  No magic bullet, at least not for me.  The bleeder setup on these (otherwise good) brembo calipers is stoooopid not conducive to easy bleeding.  Having the inlet line as high as the bleeder isn't ideal.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Midnight Rider on June 30, 2012, 12:37:30 PM
Yep, bleeding those lines can be a real aggravation.  I have not done the Brembo's, but when I put the PM calipers on the '06, it was a real PITA to get them bled, even with the vacuum kit.  I finally had to let them gravity bleed for a couple of hours or more, then do the normal routine as you describe.  No matter what, it's going to be a frustrating chore at best.  You can get the obvious air out pretty easy, but when it gets to the point of getting all the tiny air bubbles out, it's a pain.  A lovely assistant helps a bit...
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Boatman on July 12, 2012, 02:04:52 PM
Just got done rebuilding both front calipres with new pistons and seal but my noise still remains when braking.  Did not understand reply #6 about installing metal clip before tightening halves of calipre but do now.  The halves of the calipres have no aligning pins so when tightening up, the tabs where the metal clip goes can be slightly off.  Gravity bleed and then bleed with help from wife/daughter.

Thanks again, Don..
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: FLY-DOG on July 22, 2012, 08:13:56 PM
Outstanding article and very informative....thanks!!
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: TexasBowhunter on July 28, 2012, 09:11:34 AM
Nice job
subscribed for future reference
paul
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: mjonesjr84 on March 04, 2016, 04:30:05 PM
I know this is an old thread, but I've got a question.

Where did you get your rebuild kit with the pistons?
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Boatman on March 04, 2016, 05:57:32 PM
I know this is an old thread, but I've got a question.

Where did you get your rebuild kit with the pistons?

A Drag Specialties dealer such as M&M Cycle in Sandusky, Ohio..
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on March 04, 2016, 07:20:19 PM
I know this is an old thread, but I've got a question.

Where did you get your rebuild kit with the pistons?

At the time the full kits with pistons were available in the Drag catalog.  I've since been told that kit is discontinued and that the only thing currently available is the seal kits.  Barring actual physical damage from scoring or some other source there's no particular reason the original pistons shouldn't be re-used though.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: ATH on March 05, 2016, 04:02:56 PM
Twolanerider chapeau this is an excellent posting. Thanks a million for your time and effort man. This will let us all benefit from


Sent from my iPad using Tapatalk
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: ltank on March 05, 2016, 07:08:12 PM
They appear to have the same type and amount of parts as the earlier Harley brake calipers. I have redone mine even though they were working fine. Do they stop any better than the 2000 and later types?
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on March 05, 2016, 07:26:27 PM
They appear to have the same type and amount of parts as the earlier Harley brake calipers. I have redone mine even though they were working fine. Do they stop any better than the 2000 and later types?

At the time I first started messing with these I did do some measured breaking tests.  Did them from 45 and 60 to measure stopping distances before and after as well as I could master the pucker factor of going to near lockup repeatedly.  It's been long enough I don't remember the exact distances but the Brembos did stop a little shorter.  It was a repeatable difference.  Not huge but definitely real.  When you consider that sometimes 12 or 15 feet might be all the difference between stopping and wrecking even a little can be what you need.

What I do remember being far more noticeable immediately was that feedback was better.  I felt like I knew better when lockup was going to happen after making the swap. 
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: ltank on March 05, 2016, 07:54:13 PM
Ok Thanks. 
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: ltank on March 07, 2016, 11:34:18 PM
I ordered a Rear Brembo brake from a salvage yard. I hope to make it work. If I am happy with the results then I will get a set for the front brakes.  Is there any difference in pads 08 to 10
Thanks
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Yellow09SERG on March 08, 2016, 08:46:11 AM
Thanks for the write up Don.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: Twolanerider on March 08, 2016, 02:11:27 PM
I ordered a Rear Brembo brake from a salvage yard. I hope to make it work. If I am happy with the results then I will get a set for the front brakes.  Is there any difference in pads 08 to 10
Thanks

Pads fit across all the Brembo years.
Title: Re: Brembo Caliper Rebuilding -- With Pics
Post by: ltank on March 08, 2016, 11:29:04 PM
My FXR4 Master Cylinder covet says Dot5. What brake fluid is used with the Brembo calipers?  If I flush them really well or put new seals in the caliper can I use Dot5?  I hear if you mix the fluids it gels up and clogs the passage ways.