how do you rebuild calipers?

[dizasterzrfun69]

i bought all the *Edited**Edited**Edited**Edited* (seals) to rebuild a 350x front caliper, tore it apart cleaned it all and TRIED putting it back together. i got the seals in but with the seals in the piston wont go in. I wrenched down on it with a c-clamp and sheared the top o-ring into dam pieces. I tried buying a caliper on here but it seems nobody wants to sell one. is there some secret to these o-rings?

[DeePa]

plain and simple, its a *Edited**Edited**Edited**Edited**Edited*.

i used vaseline to some success.

and lots of retries

huffa posted something about it recently, so a search for it

[dizasterzrfun69]

plain and simple, its a *Edited**Edited**Edited**Edited**Edited*.

i used vaseline to some success.

and lots of retries

huffa posted something about it recently, so a search for it

when you put the seal in, it is a smaller diameter than the piston and a larger diameter than the inside diameter of the caliper. its like trying to put a 1 inch ball through a 1 1/4 inch hole without breaking anything.
i've about had it with this cobbled up POS 350x

[Dirtcrasher]

I use a tiny wire wheel on my dremel and a pick to get all the inside bore spotless. Coat them with brake fluid and sometimes a bit of grease but I haven't had that problem - fortunately...

My biggest problem is usually the slide pins that some previous moron never greased....

[hrc200x]

I use a tiny wire wheel on my dremel and a pick to get all the inside bore spotless. Coat them with brake fluid and sometimes a bit of grease but I haven't had that problem - fortunately...

My biggest problem is usually the slide pins that some previous moron never greased....


Wire wheel is a great idea, never thought about that before, I would always just get in there with some sort of pick or small screw driver and clean out the grooves.

Like the others have said, make sure the grooves are clean and grease them well. push them in strait of course. On the metal pistons I somtimes grind a little larger taper than what comes on stock.

How does everyone go about putting in those rubber boots that go on the allen slide pin?

I just got done doing 3 calipers for my '86 and '87 200x this weekend. Took almost both days to do 2 calipers and 2 master cyclinders.

Its also a bummer when you get the slide pins pressed out and the steel bushing somes with it so you have to clean that up, and reinstall it with out damage. I use one of the banjo bolts from a brake line with 3 copper washers on it, that presses them in very well.

Even after I get them cleaned and rebuilt they don't seem to work great. Maybe the mastercyclinder is weak, or rubber line so old that it expands.

[dizasterzrfun69]

[QUOTE=Dirtcrasher;613262]I use a tiny wire wheel on my dremel and a pick to get all the inside bore spotless. Coat them with brake fluid and sometimes a bit of grease but I haven't had that problem - fortunately...

QUOTE]

well thats EXACTLY what i did except i didnt use grease. :confused:

[blue27]

dremel the grooves and I run a brake caliper hone in the bore also. on the slides I also run a small wire wheel or an abrasive puffy wheel thing on the dremal to get the slide bores clean. The boots are a pain, I install a boots then carefully push the slider in, normally I do one side then push the slider through half way and install the other boot and then center the slider(if that makes sense).

[hrc200x]

blue: I think that makes sence, when I install the inner boot and push the bolt through from the outside it always wants to catch the groove in the bolt and push out. I've also ground a taper on the bolt to help slide it through the rubber.
I thought you could push the pin all the way in until the threads hit the outside pad holder and use a screw driver to push the boot in since the groove that is cut in the pin almost shows out the other side when its pushed all the way through, but this didn't work.

[dizasterzrfun69]

im going to see if the local dealer has a seal in stock today :rolleyes: it'll be 2 times what service honda costs but oh well.

[dizasterzrfun69]

not to sound dumb but did you use lube? i tried that with a c-clamp but didnt turn the piston. thats why i had an extra seal ;)

[Dirtcrasher]

If you guys hone the bore, dremel wheel the inside grooves, clean and polish the caliper and use grease - it will go together with your fingers.

Honestly, I have done a couple dozen of them and they all went together without a problem. I've used OEM and the N2 kits with no changes.

Vices and c clamps can be used but I never needed them. And, unless your vice tightening bolt and or c clamp is absolutely centered, it puts offset pressure on the piston.

Those slide pins and there mating bore are the only challenge I ever had...........

[hrc200x]

Whats an N2 kit?