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Thread: Re-build

  1. #1
    Registered User
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    Jan 2010
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    Kirtland Ohio
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    16

    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

  2. #2
    Quote Originally Posted by geozad View Post
    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
    I would recommend a good service manual.
    Paul Glaves - "Big Bend", Texas U.S.A
    "The greatest challenge to any thinker is stating the problem in a way that will allow a solution." - Bertrand Russell
    http://web.bigbend.net/~glaves/

  3. #3
    Pepperfool GSAddict's Avatar
    Join Date
    Feb 2008
    Location
    Sechelt, British Columbia
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    2,987
    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.
    Last edited by GSAddict; 03-25-2018 at 08:28 PM.
    '
    Ufda happens..........

    Need your R11xx Hall sensor rewired? PM me.

  4. #4
    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-...aliper-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-...build-kit.html

    DSC03639-M.jpg

    Lee
    Lee A. Dickinson - Danielsville, GA USA
    Airheads #3480 | Iron Butt Assn. #8914
    1992 R100RS - 1993 K1100RS - 2013 R1200GS

  5. #5
    Day Dreaming ... happy wanderer's Avatar
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    +1 on the red rubber grease.
    MJM - BeeCeeBeemers Motorcycle Club Vancouver B.C.
    '81 R80G/S, '82 R100RS, '00 R1100RT

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