Stuck brake caliper

[Big T]

There is no grease to fix this problem.
In fact, never use grease on your brake parts, except the pins some calipers slide on. Grease and brake fluid are incompatible

As to the problem of your caliper, something is very wrong there. I'm assuming the brake worked before. If so, something went wrong during your rebuild, Did you scrub out the caliper body when you had it apart? Did you clean the groove that the O ring goes in? Is the O ring a Honda part? Do the pistons slide right in if you take the seal out? What do the pistons look like? Shiny? Rusty?

More information and some pictures would help.

[LarryA_Texas]

This is maybe too obvious to even post, but mine had a small ring of crud build up on the cylinder right where the rubber meets it. Cleaning that off made them work correctly. It took some work since it was hardened, but the cylinder should be clean and smooth.

To get it out I just took the pads off and squeezed the brake lever. Fluid forced the cylinder out. Once clean it slid back in with gentle force.

[KRISTI'SGS550]

Those lubes are for external parts on the caliper: sliding pins, back side of brake pads, etc. Do not use those lubes on the internal parts like the piston and seals. The Suzuki service instructions are very clear, brake fluid only on internal parts.


.

But I'm not working on a suzuki........would a honda be different? Nothing said about lubes in the service manual.

Cory

[KRISTI'SGS550]

There is no grease to fix this problem.
In fact, never use grease on your brake parts, except the pins some calipers slide on. Grease and brake fluid are incompatible

As to the problem of your caliper, something is very wrong there. I'm assuming the brake worked before. If so, something went wrong during your rebuild, Did you scrub out the caliper body when you had it apart? Did you clean the groove that the O ring goes in? Is the O ring a Honda part? Do the pistons slide right in if you take the seal out? What do the pistons look like? Shiny? Rusty?

More information and some pictures would help.

The problem was there when I bought the bike, that is why I rebuilt the brakes. Yes, I scrubbed the caliper body and pistons after dipping them in Barryman's carb cleaner for 30 hours. I will check if the pistons slide into the caliper without the O-rings, but I am sure they do that is why I am sure it is the O-rings. Yes, the parts are all factory parts, came in Honda bags, with Honda labels and part numbers. The pistons are very clean and shiny, no rust. I will take pictures today and double check the fitting without the rings.

Cory

[Mark whiz]

Here's a quick test - take all of the seals out and just try pushing the piston on and out of the caipler bore. If it is still hard to move, you have a problem with the piston or caliper bore being crudded up or maybe warped. If the piston moves freely in the bore (as it should) then your seals are not to factory spec and should be replaced with the correct ones.

[Nessism]

Cory,
Suzuki/Kawasaki/Honda/Toyota/Nissan/BMW/Ford/Chevy/etc.... Only brake fluid on internal brake system parts. Period!

There could be scale build up in the caliper seal groove - behind the rubber seal causing it to be pushed outward. Inspect all parts very carefully. Also could be the dust seal is not installed properly causing the binding your describe. Not sure about the cause but I am very sure that grease is not allowed inside the caliper or master cylinder.

[KRISTI'SGS550]

Update:

I took the brake caliper off and cleaned everything up really good with what I had. There really wasn't anything in grooves of the cylinders and the pistons (brake) were clean with a couple inside knicks. I took the dust seals off and kept the oil seals on while sliding the pistons in and out of the cylinder. My earlier problem seems to be the dust covers. I then pulled the pistons completely out and replaced the dust seals. I put one piston in and tried to push it but it seemed stuck, so I took it out and flipped the dust deal over. I put the piston in and it slid with minimal pressure from both thumbs. I did pretty much the exact same with the next one, except it pushed in with both thumbs the first time. Both cylinders could be coaxed out using my fingers and wobbling them back and fourth. I installed the caliper back on the bike and have the brakes bleeding currently. I will update again tomorrow in the AM. I left a zip tie on the brake lever to see if I could get some air bubbles out of there over night.

Anything here sound out of the ordinary to anyone or does it sound like I am on the right track?

Nessism, thank you for the patience and setting me straight. I do appreciate all of your wisdom.

Cory

[Mark whiz]

Sounds to me like you found your problem - the piston movement you describe now is how it should be.

[KRISTI'SGS550]

OK, I got everything working, but my brake lever is still VERY spongy. As i was going the describes brake bleeding process on BassCliff's webpage I would hear an air leak somewhere in the M/C now. Should I just trash the whole set up and buy a new pair of brakes for me bike? I have nothing else to replace, tighten or adjust. I am not sure what it leaking the air, but I think it is my brand new brake line. I am tired of working on brakes.

These brakes are making me mad.

Cory

[Dogma]

OK, I got everything working, but my brake lever is still VERY spongy. As i was going the describes brake bleeding process on BassCliff's webpage I would hear an air leak somewhere in the M/C now. Should I just trash the whole set up and buy a new pair of brakes for me bike? I have nothing else to replace, tighten or adjust. I am not sure what it leaking the air, but I think it is my brand new brake line. I am tired of working on brakes.

These brakes are making me mad.

Cory

How's the tread on your sneakers?

[KRISTI'SGS550]

yeah, no joke right! I'm going to be stopping my bike old school, with my foot on the back wheel. any suggestions?

Cory

[Dogma]

yeah, no joke right! I'm going to be stopping my bike old school, with my foot on the back wheel. any suggestions?

Cory

Anything you can get done first to take a break from the uh, brakes? I sometimes catch a brainwave when I back away from something for a while.