Allow me............
CBR1100XX caliper rebuild
amateurs.............
I didn't want to use that copy, because the new XX forum software restricts the number of images in any one post, so the last 1/3 of the photos don't show in that link...
Here, lemme just cut-n-past the article over a couple of entries:
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First, you take your MityVac and suck out every trace of old, nasty brake fluid from the brake system as clearly outlined in Chap 15 of your Honda Blackbird Service Manual. Before you crack open your first bleed nipple, suck out the master cylinder until it's bone-dry:
Here is my neglected, nasty-*** crusty left front caliper:
Close-up of the pistons all caked with road splooge from 60,000+ miles of use. Bad Warchild.... dirty calipers, Bad, BAD!! :evil:
Break the caliper halves apart by removing the three caliper body bolts (12mm socket) on the non-piston side of the assembly. Note Honda's use of red loctite on the trailing threads of the bolts. You'll be working the rachet handle to the bitter end:
Pull the pistons out far enough to expose all the crusty brake spoo (yellow arrow) so you can thoroughly clean them. You could go whole hog and replace all seals at this point if you felt so inclined. Me, I elected just to clean the dog-**** out of the assembly, and keep going.
Using a non-petroleum based cleaner, scrub all the crusty road spooge off the pistons and caliper body:
Now flush your shiny-clean piston with clean hydraulic fluid and re-insert it into its respective cylinder:
Now clean out all the old dried, caked-up lube remaining inside the slider pin boots (obviously, replace these boots if they are damaged/torn):
And thoroughly lube up the interior of the slider boots with an appropriate silicone-based grease of your choice (per the manual):
Apply a thin layer of this same lube on your slider pins....
And finally, reassemble these bad boyz:
Although the Service Manual calls for new caliper assembly bolts, frankly, you're safe to use the old ones if they are in good shape, cleaned of old threadlocker, etc. Here I'm applying Loctite Blue to the trailing threads of the caliper assembly bolts prior to reassembly:
Torque these bolts down to 24ft-lbs.... now, don't be dicking this one away!!! :!:
DONE! All cleaned, lubed, reassembled and ready for some new brake pads! Although the Honda factory pads are quite excellent, me, I went with the Carbone Lorraine SBK-3 pads. :twisted:
Bleeding the system with fresh hydraulic fluid is left as an excerise for the reader......
Obviously, with the monoblock calipers the FJR uses, you won't be "splitting" the caliper halves as is shown above. Still, most all other aspects of the job are the same in principle.
