Topic: Front Brake Rebuild Questions/Bike Resurrection

[JLeather]

So, my chopper is no where near finished and it's almost spring so I need a bike.  I'm gonna be resurrecting a K1 that's been setting for about 4 years.  It's going to be my "bagger".  I'm installing hardbags to match the early Vetter fairing, swapping the HM300 eshaust out for some aftermarket pipes (so I don't damage the near-perfect stock exhaust), and swapping on a different tank/sidevocers cause I'm gonna be painting it some 70's wacky color. 

Now, the bike's been setting for about 5-6 years now.  I've removed the carbs and have begun a good rebuild on those.  It needs tires, and it needs the front brake system rebuilt.  Not sure how to go about doing this.  The front brake leaked empty while sitting.  It's not stuck, though.  I suppose there are kits for the M/C and the Caliper?  I'd like to get pads, caliper rebuild kit, M/C rebuild kit, and new hoses.  This is gonna be the long-distance bike for when I take my fiance out riding so I need ot to be safe.  Any other suggestions/problems?  Motor is not stuck, great compression, and it was running when it was parked (like all my other projects).

[mystic_1]

Master cylinder rebuild kits are available.  It's a bit of a #$%* removing the retaining circlip in the MC unless you have the special circlip pliers for this specific task.  The only thing to replace in the caliper is the piston seal, those are easily obtained too.  Since it's leaking, I'd say go ahead and replace all the banjo washers too.  Also bead blast the rotor or at least hit it with a roloc disc.

good luck!

mystic_1

[JLeather]

What's the best place to get the rebuild kits and banjo washers and stuff?

[mystic_1]

I got my caliper piston seals at the local Honda dealership, but they are available via a lot of the vendors in the Parts FAQ.  You can get banjo washers at Honda too, but bring some vaseline and loose fitting pants.  Alternately, order them online, just google "10mm banjo washer".  I got my M/C rebuild kit via eBay (seller: siriusconinc), it seems ok, however I have yet to install it so I cannot really comment on it's quality yet.

Master Cylinder Rebuild Kit:  $25.00
Banjo Washers: $3.95 per 10 pack
Caliper piston Seal: $14.00
Brake Pads: $10.00

Brakes that work:  Priceless.

mystic_1

[fixahonda]

I also used Siriusconinc from ebay for my brake rebuild stuff and it worked great for me. Everything fit fine and it now stops and releases happily.

I invented my own set of super long reach snap ring pliers out of a cheap set of Harbor Freight needle nose pliers. They are the really fine pointed ones that are always in the dollar bins toward the front of the store. I ground a bit off one of the sides for clearance and they worked perfectly.

[GammaFlat]

In the last week I took apart a bike that was sitting for 4 years and one that was sitting for 19.  Both master cylinders were dry.  I don't think either one leaked as we might deem a leak.  I would not assume that they're gonna leak if you clean everything and put them back together.  Also, I've resurrected 2 master cylinders that hadn't been used in 3 or more years and have not had to rebuild either.  Talk to me in a few weeks about the 19 year old.    For starters, I'd clean everything well... the caliper probably needs the most attention and you might need to remove the rubber ring (do this carefully or you will need a rebuild kit) and clean underneath it (and clean it well... get creative with bent coat hangers, bent picks, etc.) but I doubt you'll need a new seal.  I know I'll catch flack for this but this is based on my experience.  It's very easy to justify being super cautious with something so important as brakes and for good reason... proceed with caution. 

With a braking system that has been "dry" for a while I have found that bleeding them is frustrating.  My speculation is that bubbles form all over the place and stick in recently dry spots.  My cure for this is to beat the system up (mostly the caliper) with the handle of a screwdriver while doing the bleeding.  You'll be tapping the caliper, master cylinder and lines.  I first learned of this when I replaced a master cylinder on a car and it was in the directions to "hit the master cylinder with the handle of a screwdriver to dislodge bubbles".  I believe it to be important. 

My thoughts are that what's important in fixing up an old braking system is that when you're done, you have firm feel and your brakes return (don't stick). 

[Roscoe]

I have just received a rebuild kit for the front M/C I bought off ebay. Its the wrong one for mine. I think its for an early 750. The piston seems smaller than mine. I have a 78 CB750F2. So if you want it you can have it for what I paid, US$10.00 plus shipping. Send me a PM if you do.
Cheers
Roscoe