I had a chance recently to acquire another 04. Identical to mine but more "gently" used, so to speak. It has only 72k kms compared to my 185k. And...it has been ridden somewhat more conservatively than mine. Just what I need. Another bike. NOT. Oh well, why not.
I picked up the bike from the owner and it was all clean and shiny. I vaguely remember mine looking like that. I had about 10 miles to go to get it home. The first 8 went very smoothly as I tested out things. About 2 miles from home, a BDC decided that turning into a driveway suddenly, with no signal light, was a good idea. I hit the brakes hard and slowed to a walking pace, went around the car and....Oh Oh....the back brake would not release.
I managed to make it home but only just. The bike would not pull in 4th or 5th gear. That is how hard the brake was on. Needless to say, the disc was very hot when I got off. I let it cool down for a couple of hours and then investigated. The rear brake was on hard and the SMC had no movement in it whatsoever.
I took things apart and this is what I found:
- outboard rear pad worn wedge shaped.
I contacted Larry (Igofar) and he was only too willing and able to offer help and advice. I really don't know how he manages to keep so many balls in the air and help so many people. He truly is a wealth of knowledge and a godsend. Thankyou,Thankyou, Thankyou!!!!!
He advised that rather than just get the SMC piston rebuild kit (#20 on the parts fiche), I should get the whole subassembly (#2 on the parts fiche). Only about $60 more and you don't have the hassle of taking the old one apart (not easy) or the issue of the bore being out of round.
http://www.hondapartsnation.com/oemparts/a/hon/5053f118f870021c54be633e/left-front-brake-caliper
I installed the new subassembly and new pads. Cleaned up the caliper pistons and slides and did a complete fluid flush. A little test ride today and things seem to be back as they should.
Things to note:
1. the brakes on this bike were fine up until I did an emergency stop. It appears that a larger movement of the SMC piston put it into a corroded area and it jammed.
2. taking out the SMC piston assembly is not easy. Highly recommend replacing the whole subassembly
3. Not sure what caused the rear pad to wear like it did. All 3 pistons were freely movable.
4. Not sure if you can see, but the piston is jammed down about 0.5 cm and it will not budge. Not sure how you would get it out, short of drilling a hole in it.
Pictures:
Thanks again to Larry.(Igofar) He epitomizes what this forum is all about!!!!
Rod