Dangerously worn front brake caliper (yes, caliper)

Hey guys, lately my right-front caliper was making a grinding noise when I wheeled the bike around the garage.  I found the source of the noise and it's not good. Basically the slot where the pad retaining clip sits has been worn out and is rounded!  The pad retaining clip does not sit tightly anymore and it rides up to the point where it hits the edge of the disk.   Given enough time, what's likely to happen is the pads will come flying out of the caliper!

I suggest anyone with a high mileage sixth-gen check their calipers to see if the cutout where the little pad retaining spring sits is rounded.  If so, it's time for a new caliper!
I'm going for a ride tomorrow so I think I may need to commit some time to replacing the caliper right now.  Luckily I have a caliper from a 2006 VFR just sitting around in my garage.


Also during my investigation I discovered that the 2002-2005 caliper is WAY different to the 2006+ caliper.  The 2006 model caliper is much more beefy and its mounting point makes it sit differently against the disk.  The left-front brake caliper is also different, but the rear caliper assembly is the same from 2002 onwards.

Anyone else already know this?  

OK caliper has been changed.  Even the brake pads are different on the '06+ bikes!  Thank god I had just ordered some from Jake Wilson and ordered the "wrong" ones, which actually fit the '06 calipers!

Here are the pics of how bad the 2002 caliper with 150,000KM on it was.  I'm uploading a video of it to YouTube tonight as well.

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If your 2002-2005 VFR is high mileage, I'd be taking a very close look at your calipers.

Oh, so it's just the mounting bracket with the slider pins then. Not the caliper itself.

Really? Calipers can wear out?? Well, that's good to know!!! I'll keep it in mind, but considering the rate at which I put klicks on my '03, I'll be good for a few good years. I only got about 45,000km on it (third owner).

Thanks for the tip Kaldek!

Can I ask you to post a pic of the old and the updated beefier caliper if you can manage one without taking it off the bike? Just curious to see what it looks like...

C

[image: View Post]kaldek, on 27 January 2012 - 12:23 AM, said:

Here are the pics of how bad the 2002 caliper with 150,000KM on it was. I'm uploading a video of it to YouTube tonight as well.
If your 2002-2005 VFR is high mileage, I'd be taking a very close look at your calipers. Never seen a caliper like this. However, the number 150,000km should be a big one to consider those...

[image: View Post]Polarbear, on 27 January 2012 - 01:29 AM, said:

Really? Calipers can wear out?? Well, that's good to know!!! I'll keep it in mind, but considering the rate at which I put klicks on my '03, I'll be good for a few good years. I only got about 45,000km on it (third owner).

Thanks for the tip Kaldek!

Can I ask you to post a pic of the old and the updated beefier caliper if you can manage one without taking it off the bike? Just curious to see what it looks like...

C

Sure mate, video coming soon that shows this.

[image: View Post]Veefer800Canuck, on 27 January 2012 - 01:27 AM, said:

Oh, so it's just the mounting bracket with the slider pins then. Not the caliper itself.

Technically yes.  Part number 06453-MBG-405 (non-ABS bike).  Could be different part if the bike is ABS.

If you replaced that part you'd be good to go.

OK here's the vid.

5th gens do that too. If the rubber boot gets cracked or is torn the slider dries up and it stops floating like it should. I had to replace the rubber and grease it with high temp grease. Cleaned and polished the slider rod. Then I put a wire brush on my drill and cleaned the keep caliper slider tube and I packed it with ht grease.

[image: View Post]HispanicSlammer, on 27 January 2012 - 03:20 AM, said:

5th gens do that too. If the rubber boot gets cracked or is torn the slider dries up and it stops floating like it should. I had to replace the rubber and grease it with high temp grease. Cleaned and polished the slider rod.

I lubed the new caliper's slider pins with coppaslip grease, just in case!  I am surprised about how this happened, but maybe the pad spring needed to be replaced long ago and it moved so much over time that it caused the bracket to wear.

I did fit a new disk a few months ago, which turned out to be warped, and also my pads were worn down to the backing plate when I removed the disk.  So I had a combination of warped disk and worn pads in there.  Maybe the wear occurred really suddenly?  I guess if a few other high mileage owners (Baileyrock?) check theirs out we'll know if it's a common thing.

Good video. Probably a lot of Hondas with LBS could be subject to the same wear. Blackbirds and the like.

I noticed you were using Copper-Kote to lube the slide pins.
While that may work, I'd like to let everyone know what the proper product for this application is:
http://www.permatex....iper_Lube_1.htm

Quote

Permatex® Ultra Disc Brake Caliper Lube
An environmentally-friendly, green, nonmelting, synthetic lubricant. It is formulated to lubricate under the most adverse brake conditions, assuring that critical caliper pins, sleeves, bushings and pistons remain lubricated throughout pad life.

Suggested Applications: Caliper pins, sleeves, bushings and pistons


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There is also this stuff too, although I'm sure it is WAY more expensive, because it has EXTREME! in the name:
http://www.permatex....s_Lubricant.htm

Quote

Permatex® Ceramic Extreme Brake Parts Lubricant
This 100% synthetic lubricant contains real ceramic solids for extreme performance under the most critical braking conditions. A purple, environmentally friendly, non-melting formula, this premium lubricant is our longest lasting, most temperature resistant way to silence brake noise such as squealing and chattering; also effective in preventing long bolt and sleeve seizing and galling. Excellent on rolling and sliding surfaces operating in wet or dry conditions from -65°F to 3000°F (-54°C to 1648°C). This product assures that critical brake parts remain lubricated throughout brake pad life. Resistant to corrosion and contaminants, it will not wash out. It is compatible with internal/external brake rubber and plastic hardware, including ethylene-propylene rubber.


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Thanks mate, I removed the copper grease.  You're right, it's apparently good for threads and backing plates but not for sliders.  While there I replaced the boots as apparently copper grease causes the rubber to swell.  I used red brake grease to replace it as it's all I had handy and it's 9pm now.

Well after a good long ride today I have to say these 2006 calipers are great.  Good feel, bite, and power.  No complaints!

Good find, Kaldek..

Went to replace the left-front caliper today, but it's a bigger job than expected as you also need to replace one of the brake hoses due to a difference in length.  Means a tad more brake bleeding, as the hose has to be disconnected from the steel lines up at the headstock.   A job for a rainy day!

Thanks for posting this Kaldek.  I just checked mine and it too is worn pretty good @ 130,000kms (like yours, it was the right side calliper mount... left side was fine).  It will be replaced.