Front brake caliper rebuild.




  1. Swing the brake caliper off the disc.
  2. Using the brake lever, pump out the caliper pistons as far as you can
    without ejecting the pistons from the caliper.
  3. Disconnect the brake hose from the caliper and bring it to your work bench.
  4. Position the hose so that it doesn't leak.
  5. Remove the plug, pin, spring pad and brake pads.
  6. Using an "E12 female torx socket" remove the four caliper body bolt
    in a criss cross pattern in 2 or 3 steps.
    Note: If thread locker was used on the bolts last time it may be difficult to
    remove the bolts.
  7. Seperate the 2 parts of the caliper body and remove the 2 joint seals
    (rubber washers).
  8. To remove the pistons for the caliper body, you can use
    a "caliper piston romoval tool" or you can use compressed air. I used
    compressed air, when the pistons release they will shoot out like bullets
    so wrap the caliper in a towel and place it in a vice so that the jaws of
    the vice will stop the piston from shooting out. Invariablely one piston
    will come out easier that other so close the vice enough to prevent that
    piston from fully ejecting from the caliper, this will allow the compressed
    air to push out the other piston. Apply compressed air to one of the ports
    while sealing the the other ports, the piston should now come out.
    If you are dealing with frozen pistons then you will need the Laser
    brake piston removal kit. Applying heat with a blow torch might help
    the pistons come out a little easier. The J model piston can be tapped
    with a M16 to help pull it out.
  9. If you are reusing the pistons you must clean them, then completely
    remove any cleaner residues.
  10. If there is pitting on the nickel then the piston should be replaced
    but if thats not possible then remove and sharp edges that might damage the seals.
  11. Use a small pick to pull out the old seals, be carefull not to scratch
    the caliper as that would cause a disaterous leak later
  12. Gently clean out any dirt from where the seals are fitted with fresh
    brake fluid. If there is severe corrosion inside the seal groves
    then you will have to remove it with a pick and small rotary wire
    brush. If the seal groove is full of corrosion then the anodised layer
    has failed so you dont really need to worry about damaging it.
  13. Liberally coat each new seal in special grease
  14. After the seals are fitted coat the them in special grease
  15. Coat the sides and edges of each piston with special
    grease) and install it by pushing it in, if you push the piston in at an
    angle you might nick one of the new seals, push the piston in straight and
  16. Fit new joint seals and check that the metal that the seals touch is
    smooth and clean.
  17. Apply "thread locker/sealer" or "copper grease/anti-sieze compound" to
    the threads of the caliper body bolts (Honda reccomend thread locker).
  18. Install the bolts and tighten them in a criss cross pattern in 2 or 3 steps,
  19. Honda recomend tightening the bolts to 15 Nm when thread locker is used,
    however, if threadlocker is not used then a higher torque of 23 Nm might be