The brake system is the most important system on your motorcycle since it is responsible for your safety, and maintaining it is crucial for having it work and function properly. Brake calipers are one of the system’s main parts, and keeping them in function is vital.
So how to fix a motorcycle brake system? Remove the calipers and take off the pistons. Use a brake cleaner to clean dirt from the pistons. Use a wire brush to clean sealed channels, and caliper body faces. Spray brake cleaner on the calipers. Put some read grease on the seals, return the calipers, and reassemble the brakes.
Table of Contents
How to Fix the Brake Calipers?
What Tools and Parts are Required for Fixing the Brakes?
Here is a List of Tools That you Will Need to Perform this Process:
- Hex-drive sockets
- Socket set
- 90° Pick
- Pliers
- Caliper piston pliers
- Torque wrench
- Small drill-bit
- Protective gloves
- Wire brush and wire wool
You will also need to get these parts for fixing the brakes. A seal kit should be enough to rebuild if you have taken good care of your calipers.
Here is a List of Parts Required for Fixing the Brake System:
- Dust seals
- Stainless steel bleed nipples
- Wiper seals
- Caliper joint seals
- Bleed nipple covers
- Red rubber grease
- Copper banjo washer
Fixing your brake system requires a lot of patience and concentration since this system is responsible for your safety and the safety of other people around you.
Tip: Check the size of your pistons since different motorcycles use different sizes of them. A perfectly working brake system is crucial for your safety.
If you notice any signs of corrosion on the brake pistons, you will need to carefully clean them using wire wool, but if they are heavily damaged, you will need to replace them with the new one.
Before ordering new parts, make sure you check the model of your bike so you know the exact same type of calipers to get, so it fits perfectly.
Another part of the braking system responsible for the safety and handling of your motorcycle is the wheel bearings, so you need to understand how to check them and, in case of need, how to take them off and replace them with new ones.
Follow the upcoming steps to repair the brakes:
Step 1: Unloose the Caliper Joining Bolts and Drain out the Fluid
You first need to press the brake lever to move all the pistons out, and the braking pads touch the disc. While the calipers are on the motorcycle, take off the banjo and find a small container in which you will drain the fluid out.
In case your motorcycle doesn’t have monoblock calipers or one-side pistons, you will have to loosen the bolts which keep both sides of the caliper combined.
Note: During this step, you may also remove the bleed nipple, but you need to do it carefully because if they are seized in, they could easily snap. If you find hard trouble removing it, it would be wise to leave it for now and call a professional if needed.
Remove the calipers now.
Step 2: Remove the Pistons
Pull out any springs and retaining pins, and take the pads out after doing so. Look for hidden R-clips because some calipers have two. You will have to take out the pin from only one side, and if it is stuck, you could ease the process by applying some heat, but bear in mind that the brake fluid is highly flammable.
CAUTION: Be very careful since the brake fluid is highly flammable
If your motorcycle has monoblock brake calipers, the pistons will have to be pushed into the caliper body so that you can use the tool and remove one side at a time. While doing so, have in mind that there may be remaining brake fluid left which could splash out.
Brake piston pliers will be needed during this step. In case of having split calipers, take out the bolts and split the caliper into two halves. Use a piston plier to twist and pull out the pistons. If the pistons are in bad condition and you need to use a pair of plumbers pliers, you won’t be able to reuse them again.
Step 3: Remove the Seals
Lift the seals out of the caliper with a 90° pick. This makes the pistons bind. After doing that, take a look, and if you notice that they are corroded and that corrosion has built up behind the seals, you will see that the rubber has been pushed out.
There is a seal among the two-fluid pathways that need to be removed.
Step 4: Clean the Dirt
Use a brake cleaner and a rag to clean the pistons. Make sure that the brake cleaner completely evaporates and is never petrol-based.
Step 5: Clean the Fluid Pathways
If you find that your fluid pathways have been blocked, you need to find a way to unblock them. One thing that can come in handy in this situation is the tip of a drill, but do not use it as it is supposed to be used. Just use its tip and your bare hands and be careful to perform this step to avoid damaging the pathway.
Tip: Regular maintenance of pathways is crucial, so this kind of scenario doesn’t happen.
Step 6: Clean the Sealed Channels
Use brake fluid and spray the caliper with it. After doing so, take a pick and scrape the seal channels, so they are nice and clean. A wire brush or wire wool is nice for cleaning them properly. Take the wire wool and use a screwdriver to run it around the caliper.
Step 7: Clean the Caliper Body Faces
Clean the caliper matching faces with a wire brush.
Note: Click on this link if you want to learn How Does a Motorcycle Brake System Work.
Step 8: Thoroughly Flush the Calipers
If you notice a little bit of discolored metal inside the caliper, there is no need for worry since the most important is that the seal channels and fluid pathways are free of corrosion and cleaned. Spray some brake cleaner to make sure that the caliper is 100% cleaned. A compressor can be used for drying them too.
Step 9: Fit the New Seals and Pistons
Now you can put the pistons and in case you are putting the originals, make sure there are no lips and that you have cleaned them. Take a red grease and place a little bit of it into the seals before putting them back in their place. Use the wire wool to clean them, and if they are not smooth after that, scrap them.
If there is any larger content of red grease left on the piston, wipe it using a rag. There shouldn’t be any problem placing them back if you have cleaned them nicely.
Step 10: Fit the Two Sides back Together
Make sure not to forget the seal that needs to be placed among the two-fluid pathways. Take a tiny piece of red grease and put it on this but be careful not to take a lot of it since you could block the hole with a larger amount of grease.
The seal has to be placed in the caliper side of the recessed hole, so it doesn’t shift after bolting together. After cleaning the caliper joining bolts, take a little bit of copper grease and place it on them.
Tight the bolts with hands and after doing that, strengthen them up one side then another, lastly. Put them in the correct torque using the caliper placed carefully in a vice.
Step 11: Fit the Pads
Performing this step, there is a great chance that you will need to put a new braking pad, but if your old ones are still good to go, make sure to put them on the same side from which you took them off. Another thing to have in mind is to put the friction faces on the inside.
Do not put any copper grease on the backside of the braking pads since it is mineral-based and can cause damage to rubber components.
Replace or clean any spring clips along with the pad holding pin and the R-clips. Take a tiny amount of grease and if the pin sits well, place it on end, so there is no space for corrosion to build up or any moisture to collect.
Step 12: Return the Calipers back on the Motorcycle
Reassemble the calipers back together and torque them up correctly. You can place new stainless steel bleed nipples (TRK is a great option) if you decide to put any copper grease on them, but it is only on the top of the thread. Now you may also put a new bleed nipple dust seal.
Tighten the bolts holding the two halves of the calipers if you haven’t done it by now. Use the copper washer from the rebuild kit and refit the brake line banjos.
The final thing to do is let the new fluid in the brake system. Once you have done it, your brake system and your motorcycle are ready to go.
How to Maintain the Brake System?
In order for you to be safe while riding, you need to keep your motorcycle’s brakes in perfect condition. Your brake calipers must be clean, and pistons must be cleaned and greased. For doing so, you need to take off the brake pads, don’t press the pads into the caliper again, but unbolt it and take it off the disc. After doing so, you remove the pads and clean the pistons.
Make sure that the pads are not completely worn out and that they can still be used for many miles to go; otherwise, replace them with new ones. Use a brake cleaner for the piston and place red rubber grease in the same spot.
When returning the pads, you need to put them in the same spot you took them off; if not, they’ll need to adjust to the disc once more.
How Long do Motorcycle Brake Calipers Last? (Brakes Lifespan)
The brake calipers should be rebuilt every two to three years for most motorcycles, depending on your recommended service intervals and maintenance effort.
How to Recognize When the Brake Calipers Need to be Fixed or Replaced?
To check the calipers, you need to get the wheel off the ground and turn it; listen closely for any drag sounds while the wheel is spinning, and press the brake lever smoothly; after releasing the brake, notice how the wheel spins. If you see any bad signs like a difficult wheel rotation, consider taking further steps written below.
Conclusion
Your safety must be your top priority. The Brake system must be functional all the time because it is responsible for your safety and other traffic participants’ safety. Make sure to check your brakes before every ride to ensure everything is functional and operating.