Motorcycle Repair: frozen pistons in caliper, piston seal, honda rebel

Question
how do I unfreeze the frozen pistons in the caliper of a 1987 Honda Rebel?

Answer
Chuck, rebuild the master cylinder so it can maximize the fluid pressure, if it is not in good shape already. Using the hydraulic pressure of the master cylinder pushes the pistons out of the caliper in most cases. Just remove the caliper from the brake assembly and pump the pistons out. If one starts out before the other one, which usually happens, then put a piece of wood or a tool in the caliper housing which limits the piston from coming out all the way before the other side. Eventually, both will be expelled to the same distance, then you can just grab the ends of them and pull them free of the rest of the caliper body.

Clean the caliper body thoroughly, especially in the grooves where the piston seal ring is seated. Use new parts, lubricate with brake fluid and reinstall once again.

After 23 years, it is possible that the caliper is beyond saving.

Bill Silver