500 K1 correct return spring question ?

[McCabe-Thiele (Ted)]

This is one for Bryan or Ken probably.

I've looked at some photos of my 500 before I dismantled it, the brake pedal return spring was not fitted externally like the brake switch but was on the inside of the pivot as per the 400 fitting.

I've looked at quite a few pictures on the internet plus some I took at Stafford show and it looks as if the return spring is often fitted on the outside of the pivot shaft acting directly on the brake pedal.

Was the design changed during the various versions of the 500 K1, K2 etc ?

Does that mean there are different part numbers for the return spring ?

[SPR]

Ted

Don't know if it helps but found 3 pictures K0, K1, K2 all showing the spring on the outside ?

Always assuming they were titled correctly

K0

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K1

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K2

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[Oddjob]

It's always been fitted to the brake pedal Ted. No idea it could fit any other way, unless of course it was the wrong spring in the first place, which would explain why you couldn't find it after dismantling.

Maybe post a pic of the spring fitted beforehand?

What is odd however is the number of different way the brake adjuster bolt is fitted, 3 pics there and all are different

BTW, the correct way is the bottom pic, bolt top facing up, lock nut above the frame bracket, I'd also advice fitting a 6mm washer under the locknut so when it tightens down it doesn't cut into the new paintwork as it does so.

[McCabe-Thiele (Ted)]

I did not take a photo of the spring so maybe the reason I cant find it is because it was missing.
I took this photo on the 11th September 2022 before I first rode the bike - the rear brake was binding slightly - I removed the rear brake drum to investigate the cause the following day.



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500 brake pedal by Macabe Thiele, on Flickr

[Bryanj]

Ted, its quite possible i fitted it wrong as i was assembling a jigsaw puzzle of a bike so fitted it to work, i was happy to remember the link arm goes in before the swing arm! I assumed the slight bind was the new shoes and i think that was a relined drum

[Oddjob]

Looking at that pic Ted it's possible the rear brake was binding because I can't see a return spring, if you press the brake lever down it's probably just going to stay down and due to the adjuster bolt holding it down it may have been binding all the time.

If you intend to replace the chrome points cover let me know, I have a few NOS ones.

[McCabe-Thiele (Ted)]

Looking at that pic Ted it's possible the rear brake was binding because I can't see a return spring, if you press the brake lever down it's probably just going to stay down and due to the adjuster bolt holding it down it may have been binding all the time.

If you intend to replace the chrome points cover let me know, I have a few NOS ones.

Exactly !

[McCabe-Thiele (Ted)]

I've spent probably a total of 4 hours over 5 days in 30 minute bursts looking for a part that was never there.

The only positive is I did not loose it !!

[Johnny4428]

I've spent probably a total of 4 hours over 5 days in 30 minute bursts looking for a part that was never there.

The only positive is I did not loose it !!

Or lose it! 🤣

[McCabe-Thiele (Ted)]

I was beating myself up inside my head for not finding it - after a couple of fruitless searches anyone in earshot would think I had lost it with my  silent expletives.

[Oddjob]

I have a brake spring off something I can't recognise, came with a job lot of 550 parts but there were 400 parts and even Kwack parts mixed in so it could be off anything. It's the same gauge of wire as the OE 500 spring, I could see if I could copy mine if your willing to wait Ted, can't promise it will be any good but I'm willing to try.

[McCabe-Thiele (Ted)]

I have a brake spring off something I can't recognise, came with a job lot of 550 parts but there were 400 parts and even Kwack parts mixed in so it could be off anything. It's the same gauge of wire as the OE 500 spring, I could see if I could copy mine if your willing to wait Ted, can't promise it will be any good but I'm willing to try.

Ken, time is a commodity I have in spades - as it fits on the outside there is no hurry - I might find one in the next 6 months - if by June next year I'm stuck I will take you up on your kind offer.

[McCabe-Thiele (Ted)]

FWIW on my 500 I can fit the rear brake pedal spindle with the swing arm, rear dampers & rear wheel in place -  unlike the 400.