Disassembling front brake caliper

[MarkSims]

I have an oversize Braking front rotor that I'm trying to install on my 2000 KX250. I need to install a new caliper holder that came with the rotor.

I have the caliper off the bike and I've removed the pads and springs. The service manual now says to "remove the caliper holder, shaft rubber friction boot and cover."

The caliper holder is connected to the caliper in 2 places by "pins" - like bolts without threads (well, only threaded at the end). One of the pins is threaded into the caliper and the other is threaded into the caliper holder.

Should I be able to just slide the caliper holder off the pin threaded into the caliper? Or is there more to it than that? It seems that there must be something more holding the caliper holder to the caliper (like a nut) but I don't see it and the part diagram isn't much help.

It doesn't want to come off and I don't want to force it for fear that I'm overlooking something.

Any advice?

Thanks! Mark

 

[Hondaxrguy]

They should just slide apart. The black boots will cause some friction until the point they seperate from the place they normally sit.

Jeremy

 

[CaptainObvious]

You need to remove the pin (that the pads rest on) with a hex wrench. After that the pieces will slide apart. While you have the caliper a part, give the entire assembly a good cleaning and when you reassemble, coat he pins with some never seize.

 

[MarkSims]

I have the pin out that holds the pads at one end. The holder just doesn't want to come off. I'm wondering if the pins are corroded. I've put it a clamp and tried to knock off the holder with a hammer - but no luck.

I'm going to take it to a local motorcycle shop today and see where I'm going wrong. I think it's probably just stuck on from 4 years of no maintenance.

When I get it apart, I'm going to clean it well and replace the pads and any seals or other parts that look suspect.

Thanks for the help!

 

[MrLuckey]

From glancing at a manual it looks to me like there are two 8x40 bolt sockets that need to come out. The diagram I looked at has ref#120 and part #120P0840 for those two bolts.

You can view the diagram HERE

Select "Front Brake" and note that their will be two scroll bars on the right. One for the diagram and one for the parts list.

Let us know what you find out.

 

[CaptainObvious]

Ed, I think those are the bolts that hold the caliper to the fork. One of the pins is visable on part number 14079, the other pin is on the caliper. One the pad hanger, part number 92150, is removed the caliper should seperate. Use some force...DO NOT use heat!

 

[MrLuckey]

Ah, you're probably right RV.

 

[MarkSims]

I took the caliper to Proline Motorsports and they used a press to get the pieces apart. Ended up that one of the pins is badly rusted and was stuck.

Best part is they didn't even charge me. :yeehaw:

Thanks for all the help! Mark