2006 Honda XR125L Caliper Rebuild

[zzpza]

Before the starting problems (see other post) I noticed the brakes were not really up to spec. I took the caliper off to check and found out what was going on...

Caliper removed from bike.
https://i.imgur.com/wHVojuF.jpg

It's a Nissin one, and there's a threaded pin retaining the pads.
https://i.imgur.com/VCrXRme.jpg

Took an impact driver to get the cap off. The pin undid fine.
https://i.imgur.com/NdvdkjQ.jpg

I could then remove the manky pads, and found out that one piston was seized, and the slide bolts were seized too.
https://i.imgur.com/QJngZnZ.jpg

I found a service manual online that was very useful.
https://i.imgur.com/drwHOVu.png

I ordered a load of parts online (new pads, recon kit, new pin and cap, etc) then started the rebuild.

First order was to remove the caliper carrier.
https://i.imgur.com/Z3pz05X.jpg

Would not budge an inch.
https://i.imgur.com/mrOc0hI.jpg

I checked the exploded diagram for hidden fasteners. None found, so I reached for my weapon of choice (rubber mallet).
https://i.imgur.com/oHfnLjD.png

And gave it a whack. Free at last!
https://i.imgur.com/TYrWzNB.jpg

Why it was seized. Euu.
https://i.imgur.com/OUAMKxQ.jpg

Could do with a clean.
https://i.imgur.com/eMyGGqA.jpg

At the time, this was the fourth caliper I had rebuilt in as many weeks, so had bought a cheapo master cylinder & lever off ebay after the second one. Works a treat for getting the pistons out whilst you're sat comfortable at the work bench, and not crouched on the floor (ooo, me back!).
https://i.imgur.com/X0Y5PhW.jpg

Encouraging the stuck one to move.
https://i.imgur.com/2EvFk4W.jpg

Both free.
https://i.imgur.com/rxOsFD8.jpg

Clean pistons. You can see the line, but can't feel it.
https://i.imgur.com/zQRfoP1.jpg

Sludge in the piston. Cleaned that out!
https://i.imgur.com/K7P5jk3.jpg

New seals. Make sure to put them in the right way round! They look square, but they aren't.
https://i.imgur.com/6tzYvHh.jpg

Pistons reinstalled.
https://i.imgur.com/vOjpAMJ.jpg

Working slide.
https://i.imgur.com/WwCrUba.jpg

New pin and cap.
https://i.imgur.com/lZElMtt.jpg

New pads.
https://i.imgur.com/mxq2FQn.jpg

New bleed nipple (stainless), cap, and crush washers.
https://i.imgur.com/Qjma3l6.jpg

Back on the bike.
https://i.imgur.com/oWzjE6a.jpg

Job done.