450 front brake sticking intermittently - Honda Rebel Forum
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post #1 of 37 Old 09-10-2019, 04:47 PM Thread Starter
 
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450 front brake sticking intermittently

hello, finally i register this thing after almost a year working on it. i go to take it for a ride... as im pushing it out of the garage the front brake starts sticking intermittently. i figure its just the new pads wearing to the disc so i take it for a loop around the block to see if it gets any better... it starts smoking, smells of burning brakes and rotor is extremely hot. when i got the bike i rebuilt the caliper with a kit, replaced the pads, had the rotor resurfaced and changed the fluid. it worked ok for a loop around the block a week ago and was not nearly this bad, so i started bleeding the brakes. sometimes i can get it to not stick when i bleed it but if i take it more than 1/10 a mile it starts sticking again. so i rebuilt the master cylinder because at this point its the only thing i have not cleaned and it still will not go away. its not as bad as this morning when i didnt touch it but its by no means ridable. normally id just get a new caliper lines and master cylinder but this stupid bike is so damn hard (or expensive) to find parts for. please help im stumped on this one, the only possible thing i can think of is the rotor being warped slightly, but when i got it resurfaced wouldnt that fix that?

2002 Honda Rebel 250
1981 Kawasaki KM100
1986 Honda Rebel 450
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post #2 of 37 Old 09-10-2019, 05:08 PM
 
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Have you rebuilt the master cylinder?? or at least pull it apart and clean out the internal valve.


brake lines I order by length and fittings needed on each end from aftermarket suppliers..
rather partial to stainless braided lines..

Did you lubricate the Caliper Pins? Lithium White grease is what I use. the caliper needs to slide freely on the pins..

Yes, surfacing the disk should eliminate warpage if done properly..

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post #3 of 37 Old 09-10-2019, 05:08 PM
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If you remove the rotor and lay it on a sheet of glass, any warpage should be evident. Did you measure the thickness of the rotor after turning to see if it's still in spec? Like you, I'm wondering if the brake line is the problem. When you rebuilt the calipers, did you clean the pins the pads move on and put a light coating of silicone base grease on them?

Keepin' all the left over parts. Gonna use 'em to build another bike!

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post #4 of 37 Old 09-10-2019, 05:40 PM Thread Starter
 
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Originally Posted by flitecontrol View Post
If you remove the rotor and lay it on a sheet of glass, any warpage should be evident. Did you measure the thickness of the rotor after turning to see if it's still in spec? Like you, I'm wondering if the brake line is the problem. When you rebuilt the calipers, did you clean the pins the pads move on and put a light coating of silicone base grease on them?
the rotor is 4.5mm after the turning (spec is 4mm). i took it to a machine shop when my dad needed some other stuff machined, the guy seemed like he knew what he was doing and it came out looking near new. i completely disassembled and cleaned the master cylinder today after trying bleeding the brakes multiple times (as it was the only thing i had not cleaned up to this point). i cleaned all the braking parts on a wire brush wheel (motor with wheel attachment) including the pistons which had some corrosion (very light pitting on them after cleaning). i greased the caliper pins with brake grease and put the boots on. everything done according to the manual. i even just tried loosening the caliper bolts and squeezing the lever to align the caliper then tightening everything up (had this problem on my 250 before and that fixed it) but the problem persists.

2002 Honda Rebel 250
1981 Kawasaki KM100
1986 Honda Rebel 450
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post #5 of 37 Old 09-10-2019, 05:59 PM
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Sounds like you have covered all the bases so far. Maybe the brake line is deteriorated internally, blocking the flow of the fluid?

Keepin' all the left over parts. Gonna use 'em to build another bike!

'01 & '09 Rebel 250, '06 Ninja 250, '89 VN 750
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post #6 of 37 Old 09-10-2019, 06:06 PM Thread Starter
 
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Originally Posted by flitecontrol View Post
Sounds like you have covered all the bases so far. Maybe the brake line is deteriorated internally, blocking the flow of the fluid?
what im thinking at this point... it says 1/8" sae on the line; i cant find any new direct replacements. the part number for it is 45126-MM2-671. so how would i go about replacing the line? the connectors look ok but they look crimped onto the line somehow and i dont know i could get them off without damaging them, let alone get them onto a new line. how should i go about this? thank for the speedy responses!

2002 Honda Rebel 250
1981 Kawasaki KM100
1986 Honda Rebel 450
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post #7 of 37 Old 09-10-2019, 06:34 PM
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These guys can build a brake line to your specs. https://www.ebay.com/usr/rennsportau...p2047675.l2559

Describe the length and angle of the end fittings and they can make it up in braided stainless steel.

Keepin' all the left over parts. Gonna use 'em to build another bike!

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post #8 of 37 Old 09-10-2019, 07:08 PM Thread Starter
 
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Originally Posted by flitecontrol View Post
These guys can build a brake line to your specs. https://www.ebay.com/usr/rennsportau...p2047675.l2559

Describe the length and angle of the end fittings and they can make it up in braided stainless steel.
https://www.ebay.com/itm/115cm-45-M1...72.m2749.l2649
i ended up ordering this. i got a measuring tape for tailoring and ran it along the brake line, taping it in multiple sections. it was about 43" but i ordered a 45" line to account for any human error, better slightly longer than shorter right? i also measured the inside of the eyelet for the bango bolt with my precision caliper and it was just about 10mm (i couldnt get it to fit into the widest point but it was reading like 9.9-9.95mm so ill assume thats a 10mm). so i ordered this "universal" stainless brake line with m10 banjo fittings. lets hope this ebay special "universal" part is actually what it claims to be. ill update when its here.

2002 Honda Rebel 250
1981 Kawasaki KM100
1986 Honda Rebel 450
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post #9 of 37 Old 09-10-2019, 09:33 PM
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What you have to be concerned about is how much angle/bend there is on the fittings, and if the ends are in the same plane or offset. That line may be long enough to accomodate any "twist" in the line

Keepin' all the left over parts. Gonna use 'em to build another bike!

'01 & '09 Rebel 250, '06 Ninja 250, '89 VN 750
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post #10 of 37 Old 09-10-2019, 09:45 PM Thread Starter
 
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Originally Posted by flitecontrol View Post
What you have to be concerned about is how much angle/bend there is on the fittings, and if the ends are in the same plane or offset. That line may be long enough to accomodate any "twist" in the line
the angle on the fittings looks about the same as the one currently on the bike. thats a good point about the ends being plane or offset, why i ordered a little extra. thanks for the help! ill update when its here if its fixed.

2002 Honda Rebel 250
1981 Kawasaki KM100
1986 Honda Rebel 450
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