Re-build

I'm going to be helping my son re-build both front calipers on his R 2004 R,as one piston has been hanging up.
Any advice or helpful tips. I've already looked at u-tube videos. Thanks

geozad said:

I'm going to be helping my son re-build both front calipers on his R 2004 R,as one piston has been hanging up.
Any advice or helpful tips. I've already looked at u-tube videos. Thanks

Click to expand...

I would recommend a good service manual.

Does the bike have the original black rubber brake lines?

If so, there is a very good chance they are the cause of the caliper hanging up.
These lines are deteriorating on all '93 to '05 R,K, and F models
What happens is bits of rubber breaking free from the inside wall will block the banjo port and stop fluid from returning.
I have seen this happen on 2 bikes now.
The other risk is the line will balloon on hard braking and cause a total loss of braking.

The solution is replace with SS Teflon brake lines and flush the entire system with fresh DOT4. I can endorse the Spiegler brand, having very good success installing many sets of them. Indexable banjo's is a great feature.

Here is a tip, don't split the caliper halves. It is not necessary for the complete rebuild and the two o-rings you would need between the halves are not part of the rebuild kit, nor are they separately available from BMW. I have managed to find them as Kawasaki parts and they are also available from Bevel Heaven...

https://store.bevelheaven.com/Brake-Related-Parts/Brembo-Caliper-O-Ring/

Another tip would be to lubricate the new sealing rings with red rubber grease instead of brake fluid when you reassemble...

http://www.redrubbergrease.com

http://www.redrubbergrease.com/tips-how-to-brake-caliper-failure-repair-with-rebuild-kit.html



Lee

+1 on the red rubber grease.