Brake rebuild not going so well

[machineman2101]

Hey guys, i'm having trouble with a brake piston that just doesn't want to come out.
I've tried pumping brakes, air, and gently grabbing the piston to try and wiggle a little but no luck.
I got one to come out but the other will not budge!
Any ideas would be greatly appreciated.
Also, I bought a brake rebuild kit and it didn't come with the boots for the brake caliper bolt.
Anyone know where I can just get those boots?

83 gl1100i

[trike lady]

Had the same problem rebuilding the rear caliper on a GL1200. It took two people to get the stuck one out, one to hold the caliper and twist it and the other to use a pair of vice grips on the piston to twist it and it eventually came out.
Clean the caliper bores well before rebuilding, the slider pins and remove any rust from caliper hardware. Make sure everything is super clean and place all the parts in brake fluid for assembly (O-rings and pistons).
You may want to contact the local Honda dealer for the boots.

[machineman2101]

Had the same problem rebuilding the rear caliper on a GL1200. It took two people to get the stuck one out, one to hold the caliper and twist it and the other to use a pair of vice grips on the piston to twist it and it eventually came out.
Clean the caliper bores well before rebuilding, the slider pins and remove any rust from caliper hardware. Make sure everything is super clean and place all the parts in brake fluid for assembly (O-rings and pistons).
You may want to contact the local Honda dealer for the boots.

Will call the dealer, thanks

[WingAdmin]

Vice grips?!?!! Don't plan on ever using that piston again afterwards....and they are not cheap to replace!

It's actually much easier than you think. Take a piece of flat metal, or even an old brake pad, and put it in the caliper:



While holding the metal in place, have an assistant pump the brakes. This will push the pistons out of the caliper. Usually one piston is hung up more than the other. Without the metal, one piston will come all the way out, leaving the other one hopelessly seized in the caliper. Using the metal, the piston is not allowed to completely eject from the cylinder. Once it hits the metal and stops, the remaining piston is forced out. Make sure you don't run your brake fluid reservoir dry while doing this - add some brake fluid if necessary.



See more: How to rebuild your rear brake caliper

[trike lady]

The ones that came out of the 1200 caliper were dinged and scored, just in very poor shape.
An entire rebuild kit was ordered and new pistons. When it was (supposedly) rebuilt the first time and the bike was taken on a test ride the rear brake locked up. I rebuilt the caliper correctly, cleaned it very well and coated everything internal, O-rings and pistons in brake fluid and grease on the pins; on the test ride the brakes worked perfect.
I hope the pistons aren't that stubborn, like the ones I dealt with.

The pistons in the rebuild photos are in better shape than the ones I pulled out.

[machineman2101]

Actually I had to use a c clamp on the piston that was moving to help get the one that wasn't moving out. Must've had air in the lines.
But it came out. Thanks for the help!

[wingwrench]

Partszilla.com has the boots listed...and you can buy just the boot..each part is sold seperatly .. So if you don't need the whole kit you can just buy the parts you need...

[wingwrench]

I had the same problem with one piston comming right out and the other one not moving at all. I used a small wrench to hold the moving piston from comming all the way out and had the wife pump the brake peddle.. She had to really STOMP on it a few times before it started to move..Hope this helps thenext guy.....Goldwingdocs....Rocks...!

[made2care]

Manual clearly states , do not attempt to take apart and rebuild. Special tools required. However , I am by no means underestimating the abilities of forum members, since there are success stories on this. Since I have never rebuilt any, I tend to lean to the side of caution. Then again , there's a first time for everything , so have at it

[WingAdmin]

Manual clearly states , do not attempt to take apart and rebuild. Special tools required. However , I am by no means underestimating the abilities of forum members, since there are success stories on this. Since I have never rebuilt any, I tend to lean to the side of caution. Then again , there's a first time for everything , so have at it

Brake caliper rebuilding is a normal maintenance item - and is why rebuild kits are commonly sold. I've rebuilt quite a few, and I don't think there are any really special tools or skills required.

[dingdong]

There is a long list of required "special tools" in the service manual. All for sale by Honda of course. None of which I have had to purchase. Some I have self made but most not needed.

[wingwrench]

A mityvac is handy for bleeding the brakes... Other then that a few wrenches
all that is really needed. I have an 83. Gl1100 with a gl1500 trunk and bags and I don't even remove the left bag any more.. Just reach up from underneath and unbolt the caliper...

[dingdong]

A mityvac is handy for bleeding the brakes... Other then that a few wrenches
all that is really needed. I have an 83. Gl1100 with a gl1500 trunk and bags and I don't even remove the left bag any more.. Just reach up from underneath and unbolt the caliper...

We sure would like to see some pics of your bike.

[robb]

Was the piston all the way in or out a little. If out a little place pad over piston and apply pressure with a c-clamp or large pliers. Seen a few times that master cylinder was blown out trying to free a piston. Can turn it up and fill outer opening with penetrating oil and let set overnight.

I drop calipers in a bucket of carb cleaner and 4 hours later they look like new and fall apart in your hand. Two gallon bucket kit for about $20, five gallon kit for around $40

[linkbelt]

I don't mean to hi-jack this thread but where can I buy a Mity-vac mentioned here? I have had issues with rear brake dragging so am having my rear master and caliper rebuilt and changing the brake lines. I would like to make sure I get the system bleed properly.
Thanks

[WingAdmin]

I don't mean to hi-jack this thread but where can I buy a Mity-vac mentioned here? I have had issues with rear brake dragging so am having my rear master and caliper rebuilt and changing the brake lines. I would like to make sure I get the system bleed properly.
Thanks

You can get one at Amazon: MityVac MV8000

[robb]

Walmart

http://www.walmart.com/ip/Mityvac-Autom ... t/22849472

[linkbelt]

Thanks guys, not available @ Walmart.ca but found and purchased from Amazon.ca.