fitting caliper bracket

[MIKE550/4]

thought this would be a simple task, spoke to bryan and thought I would post some pics,

simply line up caliper bracket and mudguard and insert 2 bolts, done this first time and caliper rubs on disc as does the shield

cannot do it second time round as you have to push down the mudguard and line up caliper and put in bolts

problem is the bolt wants to go in at an angle

sure the caliper arm is on correct f on arm facing right on bike as you sit on it

so all stripped and left while I have a rethink.... it was all going to well

[MIKE550/4]

I have my caliper hanger sandwiched between the guard and fork is that correct ?

[MIKE550/4]

please be critical mate I need to get this right

let me add more info,  caliper front and rear part and arm were powdercoated, I fitted these dry as a tryout, as they were stuck together but now apart

adjuster bolt does have the spring in the middle and a washer and nut on the outside ( hard to see in pic but its there )

disc is one that came with bike as are the nuts to hold them on so obviously wrong

more research needed, the pivot arm maybe causing a lot of the problem as it does not move up and down


thanks for help please bear in mind though complete novice first bike rebuild,
lots of issues here

[MIKE550/4]

also confused by the nuts which hold the disc on

ones I have I am sure are these

http://www.cmsnl.com/honda-cb550k3-four-england_model14671/nut-hex-8mm_90309357000/

[hairygit]

Don't panic about the disc retaining nuts, they ARE correct, Honda changed from plain nuts and locktabs to what they called usb nuts, which your bike has fitted. They are serrated on the thrust face, so act as locknuts, no washer or other fixing required, they also fitted the same nuts to later 750 discs as well (K5 onwards I think), my 750F1 has those later nuts and work perfectly! I would suggest completely removing the adjuster bolt and spring for now, grease that pivot pin, and all should be well when you put the caliper halves together. The purpose of the adjuster bolt is to pull the fixed pad against the spring pressure, and hold the fixed pad 6 thou from the disc, but as you cannot check that measurement before the caliper is bolted up properly, it just gets in the way causing the problem you have, so put it back AFTER the caliper is together

[Ewan 500 K1]

Oddjob ... the 550K3 parts diagram doesn't show those double tag washers , it has those shouldered nuts instead.... edit .. woops as hairy git says !

Mike ..  oddjob pretty much covers it all apart from the double tag washers issue. (just for info these were used on earlier 550s and the 500, phot attahed shows them) edit .. acht flippin pictures still not uploading !
1) what happens if you miss out the adjuster bolt like oddjob (and hairygit) says ? The phots make it look like the adjuster bolt is pulling things out of alignment the way you have it set up

2) when you say that the pivot arm doesn't move up and down ... you mean part number 9 in the attached diagram doesnt slide up and down on part 10 ?  and thus that you cant get part 10 off of part 9 ? If thats the case , you probably need to adress that as an issue. Get the pivot pin out of the pivot arm and give them a good clean , grease them and make sure that you have an o-ring top and bottom of the pivot arm. Like oddjob says there should be no gap between the bottom of the rear pin (Part 10) and the pivot arm (part 9) ... but your photo shows a gap of quite a few mm in your third picture

http://www.motogrid.com/p/OEM-Parts#/Honda/CB550K_A_(78)_MOTORCYCLE%2c_JPN%2c_VIN%23_CB550K-2100001_TO_CB550K-2122082/FRONT_BRAKE_CALIPER/CB550K-78-JPN-A/2Y134043F13404308A


3) have you got a proper honda shop manual ?

[MIKE550/4]

ewan

exactly that it does not go up and down but does rotate, and no  o rings

so will strip, grease get correct o ring and rebuild and report back, the main problem, this should fix then

I have taken note about spring washers to be added and the bottom collar to be turned and spring washers to be added

[MIKE550/4]

thanks guys

least I know what direction to take,  first port of call is this pivot pin

[Ewan 500 K1]

I fitted a grease nipple on the rear of the arm just so I could get some grease in there without stripping it.

thats a great idea

[Ewan 500 K1]

Easy to do Ewan so long as you position it correctly.

First the pivot pin has a small area on it which sits lower than the rest, it's right in the middle so that's where you need to position the nipple. The downside is that the surface on the outside of the arm is round, I filed down a small area so it was flat, used a right angled nipple off a 250N swinging arm IIRC, drilled a small hole and tapped it to suit the nipple thread, a small washer to help seal the hole between the nipple and arm and job was done. Worked great, a quick squeeze on the grease gun and grease was pouring out of both top and bottom of the pivot pin.
I fitted one on the rear brake arm pivot as well plus I fitted a central one on the 500s swinging arm, I never liked the 2 fitted on the outside so I drilled a hole, welded a 6mm nut onto the arm and used that to mount the right angled nipple, I then had the swinging arm chromed. I much prefer this method of getting grease onto the pivot bolt, I still use the 2 outer ones to grease the bushes and the central one to grease the outer surface of the bolt.

cheers Ken , I'm on it ... just ordered a couple of M6 grease nipples. I guess that you orientated the nipples so that they point to the outside of the bike ? This has got to be front brake tip of the year

[MIKE550/4]

hi

managed to get the pivot pin  out today, pin is now free, 2 orings in a recess at each end and greased and put back


hopefully now it should line up better,  the gap at bottom has now gone as in previous pic,will post up new pics later in week

thanks for all the help

[MIKE550/4]

so pivot pin regreased, spring washers attached to bottom mudguard and end of forks

for the bolt that holds on the caliper bracket and mudguard only room for flat washer and nut

it all seems to sit better so looks correct, also gapping on collar looks correct

comments welcome and promise I am taking it onboard