Question about 2000 Harley Davidson FLHR-FLHRI Road king

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I need to rebuild both of my front calipers on my 2000 FLHPI. The pistons are sticking, so I bought the seal kits (rebuild kits). Now, aside from disassembling the calipers, what should I do to free the pistons and clean the calipers before re-assembling them and re-installing them?

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  • Harley Davidson Master
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If by "disassembling the calipers" you mean splitting them open, DO NOT do that.
You detach the caliper so that you can remove the pads and get at the piston, but then what you should do is to simply pop the piston out.
That can be done simply by pumping the brake pedal, using air pressure (with a rag to prevent the piston from flying around), or with a grease gun.
Then once the piston is out, you simply wire brush any corrosion off. If the piston is so pitted that it can not be made smooth and will leak, then it should be replaced.
If you wash them out with anything other than brake fluid, then be sure to blow out any residue with compressed air.
Use lots of brake assembly lube, and ensure the new dust seal is water tight. Bleeding the brakes will flush out any remaining dust.

Posted on Oct 04, 2010

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