2009-2010 Honda CRF450R – Front Caliper Rebuild

0
106

How To Service The Front Brake Caliper On Your 2009 – 2010 Honda CRF450R

2009 - 2010 Honda CRF4504 - Brakes - Front Caliper ServiceThe Tools You Will Need Are:

  • 12mm Socket
  • 10mm Socket
  • 5mm Hex Socket
  • 8mm Wrench
  • Screwdriver
  • Small pick
  • Non-Metallic Stiff Brush
  • Calipers
  • Brake Cleaner

The Parts You Will Need Are:

  • ’09-’10 Honda CRF450r Front Caliper Rebuild Kit
  • Fresh DOT 4 Brake Fluid
  • Rubber Grease

This front caliper rebuild on your 2009-2010 Honda CRF450r should cost around $25 and take about 45 minutes to complete.

Pre-Service Notes

  • I recommend opening the Service & Torque Specs in a new tab for easy reference.
  • If you need parts and tools, make sure to buy them here!
  • Pictures with captions are after the steps below.
  • Brake fluid will damage everything, so keep your shop towels ready!
  • If you need any help don’t hesitate to ask!

Caliper Removal

  1. Remove the brake pad pin plug, followed by the brake pad pin, and remove the brake pads, but leave the front caliper mounted.
  2. Pump the brake lever to extend the pistons, using the brake disc as a backstop.
  3. If you take your caliper off the fork and pump the pistons out, they may not extend evenly, like this one.
  4. When the pistons have reached the brake disk, remove the banjo bolt, then remove the front caliper.
  5. Make sure to wrap the end of your brake line with a paper towel.
Remove Pad Pin Plug
Remove Pad Pin Plug
Pull The Brake Pads
Pull The Brake Pads
If you take your caliper off the fork and pump the pistons out, they may not extend evenly, like this one.
If you take your caliper off the fork and pump the pistons out, they may not extend evenly, like this one.
Even Out Front Caliper Pistons
Even Out Front Caliper Pistons
Remove The Banjo Bolt
Remove The Banjo Bolt
Wrap Your Brake Line!
Wrap Your Brake Line!

Front Caliper Disassembly

  1. If your pistons are hard to remove, you can CAREFULLY remove them with pliers wrapped in electrical tape.
  2. Remove the slide pin boots, bleeder valve, and piston seals.
  3. Be very patient when removing the piston seals.
CAREFULLY Remove The Pistons From The Front Caliper
CAREFULLY Remove The Pistons From The Front Caliper
Remove Slide Pin Boots
Remove Slide Pin Boots
Remove The Bleeder Valve
Remove The Bleeder Valve

Clean And Inspect

  • Clean All Front Caliper Components

    1. The components need to be free of brake cleaner residue before assembly.
    2. You can wash everything down with brake fluid and a clean towel, or you can rinse and scrub with water. I don’t recommend using water unless you have compressed air to completely dry the front caliper body.
Clean Everything On The Front Caliper
Clean Everything On The Front Caliper
Blow Out The Caliper Body
Blow Out The Caliper Body
  • Inspect

    1. Check the caliper components for any signs of noticeable wear or damage.
    2. One of these pistons is pitted, so I will need to sand that down.
    3. Check the slide pins for any rough areas that could bind. If you feel anything, gently sand it with fine-grit emery paper until smooth.

2009-2010 Honda CRF450r - Brakes - Inspect

  • Measure

    1. Measure the inside diameter of the piston bore and the outside diameter of the piston.
    2. The piston bore should be no Greater than 27.060mm, and the piston should be no LESS than 26.853mm.
    3. If your front caliper bore and pistons are out of spec, they need to be replaced.
2009-2010 Honda CRF450r - Brakes - Inspect
Measure the inside diameter of the piston bore.
2009-2010 Honda CRF450r - Brakes - Measure Pistons
Measure the outside diameter of the piston.

Related: How to reverse bleed the brakes on your freshly rebuilt brake system.

New Brake Parts

  1. Before assembly, take stock of your new parts. Do you need parts?
  2. I am installing an All Balls rebuild kit that includes a new set of slide pin boots, bleeder valve cap, pistons seals, banjo bolt seal washers, and slide pin.
  3. Make sure to match the old parts with the new ones, so you don’t throw away something you need.
  4. Soak your new piston seals in fresh brake fluid for 15 minutes before assembly.

2009-2010 Honda CRF450r - Brakes - New Front Caliper Brake Parts From All Balls Racing

2009-2010 Honda CRF450r - Brakes - Soak New Seals

Caliper Assembly

  1. Give the caliper bore one last wipe just to be safe.
  2. Install the piston seals, immediately followed by the pistons.
  3. Make sure your pistons are aligned as flat as possible, then install them in a twisting motion.
  4. Install the slide pin boots, the short boot goes on the bracket, and the long boot goes on the body.
  5. Install the bleeder valve cover, then the bleeder valve.
  6. Grease the slide pin boots with rubber grease, assemble the bracket and body, and give the bracket a few pumps to evacuate any trapped air in the boots.
  7. If everything feels smooth, pull the bracket off and install the brake pad retainer, then reassemble the front caliper.
Install the piston seals, immediately followed by the pistons.
Install the piston seals, immediately followed by the pistons.
Install The Front Caliper Pistons
Install The Front Caliper Pistons
Install Slide Pin Boots
Install Slide Pin Boots
Install Other Slide Boot
Install Other Slide Boot
Install The Bleeder Valve
Install The Bleeder Valve
Grease The Slide Pin Boots
Grease The Slide Pin Boots
Give the bracket a few pumps to evacuate any trapped air in the boots.
Give the bracket a few pumps to evacuate any trapped air in the boots.
Install The Brake Pad Retainer
Install The Brake Pad Retainer
Reassemble The Caliper
Reassemble The Caliper

Front Caliper Installation

  1. Mount the caliper and install the banjo bolt with new seal washers.
Mount the caliper.
Mount the caliper.
Install Banjo Bolt On The Front Caliper
Install Banjo Bolt On The Front Caliper

Front Caliper Torque Specifications

Banjo Bolt25 ft-lbsMounting Bolt23 ft-lbs

Keep Your ’09-’10 CRF450r Running Right!

If you have any questions or anything to add, please leave them in the comments or on our FaceBook page!

This site uses Akismet to reduce spam. Learn how your comment data is processed.