Warning: If a caliper indicates the need for an overhaul (usually due to leaking fluid or sticky operation), all old brake fluid should be flushed from the system. Also, the dust created by the brake system may contain asbestos, which is harmful to your health, Never blow it out with compressed air and don't inhale any of it. An approved filtering mask should be worn when working on the brakes. Do not, under any circumstances, use petroleum-based solvents to clean brake parts. Use clean brake fluid, brake cleaner or denatured alcohol only.
Removal
1. If the caliper is just being displaced and not completely removed or overhauled, do not disconnect the brake hose. If the callpei is being completely removed or overhauled, remove the brake hose banjo bolt and detach the hose, noting the alignment with the caliper (see illustrations). Plug the hose end or wrap a plastic bag tightly around to minimise fluid loss and prevent dirt entering the system. Discard the sealing washers as new ones must be used on installation. Note: If you are planning to overhaul the caliper and don't have a source of compressed air to blow out the piston, just loosen the banjo bolt at this stage and retighten it lightly. The Dike's hydraulic system can then be used to force the piston out of the body once the pads have been removed. Disconnect the hose once the piston have been sufficiently displaced.
![](https://motoinstruction.ru/img/honda/19/125832.jpg)
5.1a. Brake hose banjo bolt (arrowed) - XL600V
![](https://motoinstruction.ru/img/honda/19/125833.jpg)
5.1b. Brake hose banjo bolt (arrowed) - XL650V and XRV750
2. If the caliper is being overhauled, remove the brake pads (see Section 2). then slide the caliper off the bracket, noting how it fits (see illustration).
![](https://motoinstruction.ru/img/honda/19/125834.jpg)
5.2. Slide the caliper off the bracket
3. If the caliper is just being displaced, on XL600V models unscrew the bolt securing the brake hose clamp to the caliper bracket (see illustration 2.32c). Unscrew the caliper rear mounting bolt/slider pin, then pivot the caliper up off the disc and slide it off the bracket, noting how it fits (see illustration 2.35c and 5.2).
Overhaul
4. If required, remove the pad spring from the caliper and the guide from the bracket, noting how they fit (see illustrations).
![](https://motoinstruction.ru/img/honda/19/125835.jpg)
5.4a. Remove the pad spring (arrowed)...
![](https://motoinstruction.ru/img/honda/19/125836.jpg)
5.4b ...and the pad guide (arrowed)
5. Clean the exterior of the caliper with denatured alcohol or brake system cleaner (see illustration).
![](https://motoinstruction.ru/img/honda/19/125837.jpg)
5.5 Rear brake caliper assembly: 1. Piston; 2. Dust seal; 3. Piston seal; 4. Bleed valve; 5. Caliper; 6. Pad spring; 7. Boot; 8. Mounting bolt/slider pin; 9. Collar; 10. Slider pin
6. Remove the piston from the caliper body, either by pumping it out by operating the brake pedal, or by using compressed air. If the compressed air method is used, places wad of rag over the piston to act as a cushion, then use compressed air directed into the fluid Inlet to force the piston out of the body Use only low pressure to ease the piston out.
II the air pressure Is too high and the piston i forced out. the caliper and/or piston may be damaged.
Warning: Never place your fingers in front of the piston in an attempt to catch or protect it when applying compressed air, as serious injury could result. Place the caliper piston side down on a bench, with the rag between them, and let the air lift the caliper off the piston.
Caution: Do not try to remove the piston by levering it out, or by using pliers or any other grips.
7. Using a wooden or plastic tool, remove the dust seal from the caliper bore. Discard it as a new one must be used on installation. If a metal tool is being used, take great care not to damage the caliper bore.
8. Remove and discard the piston seal in the same way.
9. Clean the piston and bore with denatured alcohol, clean brake fluid or brake system cleaner. If compressed air is available, use it to dry the parts thoroughly (make sure it's filtered and unlubricated).
Caution: Do not, under any circumstances, use a petroleum-based solvent to clean brake parts.
10. Inspect the caliper bore and piston for signs of corrosion, nicks and burrs and loss of plating. If surface defects are present, the caliper and/or piston must be replaced with new ones. If the necessary measuring equipment is available, compare the dimensions of the piston and bore to those given in the Specifications Section of this Chapter, replacing any component that is worn beyond its service limit. It the caliper is in bad shape Ihe master cylinder should also be checked.
11. Remove the collar from the rear slider pin rubber boot and remove the boots from the caliper and the bracket (see illustrations). Clean off all traces of corrosion and hardened grease from ths collar, boots and pins. Renew the rubber boots if they are damaged, deformed or deteriorated. Apply a smear of silicone based grease to the collar, boots and slider pins. Fit the boots into their bores, then lit the collar Into the rear boot (see illustrations 5.11b and a).
![](https://motoinstruction.ru/img/honda/19/125838.jpg)
5.11a. Withdraw the collar (A) and remove the caliper boot (B)...
![](https://motoinstruction.ru/img/honda/19/125839.jpg)
5.11b ...and the bracket boot
12. Lubricate the new piston seal with clean brake fluid and fit it in its groove in the caliper bore.
13. Lubricate the new dust seal with clean brake fluid and fit it in its groove in the caliper bore.
14. Lubricate the piston with clean brake fluid and fit it closed-end first into the caliper bore. Using your thumbs, push the piston all the way in. making sure it enters the bore squarely.
Installation
15. If the caliper has not been overhauled, remove the collar from the rear slider pin rubber boot and remove the boots from the caliper and the bracket (see illustrations 5.11a and b). Clean off all traces of corrosion and hardened grease from the collar, boots and pins. Renew the rubber boots if they are damaged, deformed or deteriorated. Apply a smear of silicone based grease to the collar, boots and slider pins. Fit the boots into their bores, then fit the collar into the rear boot (see illustrations 5.11b and a).
16. Make sure that the pad spring and pad guide are correctly fitted (see illustrations 5.4a and b). Slide the caliper into the bracket (see illustration 5.2).
17. If removed, install the brake pads (see Section 2). If the pads are already installed, pivot the caliper down onto the disc while keeping the pads held in position, locating the leading edges correctly against the guide on the bracket (see illustration 2.35b). Apply a suitable non-permanent thread locking compound to the rear mounting bolt/slider pin and tighten it securely (see illustration 2.35c).
18. If detached, connect the brake hose to the caliper, using new sealing washers on each side of the fitting. Align the hose as noted on removal (see illustration 5.1a or b).
Tighten the banjo bolt to the torque setting specified at the beginning of the Chapter.
19. Fill the master cylinder reservoir with DOT 4 brake fluid (see Daily (pre-ride) checks) and bleed the hydraulic system as described in Section 10.
20. Check for leaks and thoroughly test the operation of the brake before riding the motorcycle.