Front brake caliper rebuild

[LarDog]

I just bought a 1983 650 Nighthawk. It needs some front end work. I took the front forks off and I will be replacing the seals and bushings. While I'm waiting for parts I took a closer look at the front calipers. They were very dirty from the fork oil leaking on them. There was also a piece of rubber gasket/o-ring sticking out by both caliper pistons. I went online to see what that could be. It must be the Dust Seal and/or the Piston Seal. Are these easy to replace? Has anyone done this?

Thanks,
LarDog

[JohnC]

I've not done one on a Nighthawk, but I've done one on an FZR. Not a difficult job, really. Just gotta make sure the bores are smooth and you use the supplied grease.

[brokerecord]

A 650 Nighthawk, one of my all time best looking bikes.

[Bigdaa]

Brakes being that old, you better pop the pistons out and do the whole rebuild. That's o-rings and dust seals plus honing the bore and you may consider putting in new pistons to boot. In order to get the pistons out, use compressed air in the hydralic port while holding the caliper in a thick towel so as not to damage the piston when she blows. An auto parts store will have the cylinder hone. You chuck it up in a drill motor, lube the stones with fresh brake fluid and run it in and out of the cylinder a couple times to get a nice cross hatch pattern.
Also, you might consider putting new brake lines on as they probably have decomposed somewhat with age and exposure.


To save some trouble, you might take the calipers to a decent mechanic and have him rebuild them for you. Same with the fork seals. Either way, hope you get that bad girl on the road soon.


Bigdaa

[async]

They were nice looking bikes for their day. Looks like a drum brake on the rear.

[Bigdaa]

The motors had hydralic lifters..........no valve adjustment, ever!

[LarDog]

I think I'll give it a try...thanks. The manual I have doesn't have any info on rebuilding the calipers. I'll have to look around before I start.

[Bigdaa]

Might want to pick this up:


http://www.amazon.com/Honda-Cb550-Ni.../dp/0892874201


It will make for excellent late night reading and will cover your future mechanical escapades.

[brokerecord]

Thanks for the pic, just look at the bike and then look at the Red 919, looks kinda like a Son that hangs out in the gym all day, huh!

[97af]

I shot a buddy of mine in the thigh with an air propelled caliper piston from a GS1100 quite a few years ago.It was hillarious from my point of view.......
I've since used a grease gun to push the pistons out of the last few calipers I've rebuilt.Alot more controlled,a whole lot more mess,but no drama.