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I rebuilt the rear brake caliper on my Harley 2004 Dyna low rider and it still will not return causing the brakes to heat up. I've bled the brakes three or four times. After rebuild.

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I am not familiar with the model or the design of the caliper but I have a few thoughts, assuming it is a hydraulic system.

There have been a few cases where a caliper has been a hybrid construction using an iron caliper frame and aluminium cylinder(s). Corrosion tended to build up in the joint between the components and cause the cylinders to be squashed into an oval shape so the piston would still bind even when everything appeared visually perfect and tested together without seals and dust cover...

It is important no residual pressure is present in the hydraulic line that will keep the brake pads in contact with the disc. If the brake releases when the bleed nipple is opened the problem is residual pressure, probably due to the master cylinder not returning fully.

Some hydraulic caliper seals are square section and can be fitted either way around into a thoroughly cleaned groove. Other seals are wedge-shaped and must be fitted the correct way around. The wedge is typically very slight and not immediately obvious.

As the piston is pushed out under hydraulic pressure, it distorts the seal. When the pressure is removed the seal regains the original shape and as it does so it pulls back the piston approx 2/3 thou. The main hydraulic seal is the piston return spring which should be quite adequate if the disc is in good order and the pads are free to move easily in the carrier.

Posted on May 06, 2017

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Posted on Jan 02, 2017

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