Topic: Front end rattle - brake caliper mount

[The Lone Builder]

My bike developed a rattle at the front end, starting intermittently, but quickly becoming continuous - in the sense that every time we hit a bump it rattled. I traced this to the brake caliper mounting bracket.

This was dismantled, the tattered o-rings - one was in fact torn – replaced and a copper washer put in at the top end  of the pin. 500 km later the situation was as bad as ever.

Another dismantle and this time a thin wire was wound around the pin to supplement the washer that looked a bit crushed. A thicker split pin was also inserted.

500km later, bad as ever!

Now I’m back home - oh, forgot to mention that this all happened on a 4,500km road trip that I’ve mentioned elsewhere. I searched the forum and discovered that this is not an uncommon problem.

I dismantled everything, yet again and did a few measurements. The holes in the mounting arm were clearly ovalled  and the pin itself worn - 9.7 vs a nominal 10mm. The o-rings, replaced only 1,000km ago were tattered.

I had a spare bracket and measured it up, not that this was necessary because there was no play to talk of, but the hole was round and the pin measured 10mm. There were also no shims in this one as compared to the “old” one which was shimmed to a total of 0.15mm.

Hopefully problem solved.. I just worry now if the replacement bracket will go the way of the original on Africa’s roads.

[754]

Once it starts to wear, it wil wear very quickly, it's likely bouncing back and forth in there.

[Johnie]

I believe Honda issued a tech bulletin on that and putting a shim in there.

[my name is nobody]

I believe Honda issued a tech bulletin on that and putting a shim in there.

They did, and I saw it on here someplace, but can't find it now. Raul Guellego (sp)?
posted it. Could a steel insert be machined by someone to combat this condition?
Maybe using the bushings from a car door? I have never tried, just throwin it out there..

[mattsz]

I believe Honda issued a tech bulletin on that and putting a shim in there.

Found this posted on the UK SOHC forum - is this it?

[The Lone Builder]

I believe Honda issued a tech bulletin on that and putting a shim in there.

Found this posted on the UK SOHC forum - is this it?

What did you find? There was nothing showing in my view.

Rapid wear is right. From no noise at all to something reminiscent of a train going over the tracks, but without the rhythm, in a couple of thousand km’s.

The old one I took off did have shims in place – 1.5mm in total. The holes were ovalled though: 10.48/10.3 and 10.01/10.2 and teh pin measured 9.72mm

The replacement bracket has no space for shims; the holes are round at 10.01mm and the pin 10mm.

 Fingers crossed.

[mattsz]

What did you find? There was nothing showing in my view.

Huh.  I posted a link to a jpg scan of the bulletin. Not sure why you can't see it, the image shows on my screen, even in your reply's quote of my post!  I've included it as an attachment below, hopefully that will work for you...

[The Lone Builder]

Thanks.

All I see is a little square box. 

[bryanj]

Has to be a problem on your system i got bulletin on dumbfone and laptop

[mattsz]

Thanks.

All I see is a little square box. 

You can't view the attachment, either?  Huh.  Not sure how else to help, unless you want me to email it to you...

[mattsz]

Try this dropbox link:

https://www.dropbox.com/s/01jfp6wxlum9fdo/Front%20Brake%20Service%20Bullitin.jpg?dl=0

[Don R]

 Thanks, I have that rattle on a sandcast.

[Trevor from Warragul]

Drill a hole, tap a thread, insert a grease nipple...

[The Lone Builder]

Drill a hole, tap a thread, insert a grease nipple...

Trevor, I'm resurrecting this post because the problem has resurfaced.
Looking at your pic, I was trying to work out where you placed the nipple. I'm guessing you had a later calliper holder - parts 5 & 13 in the pic as opposed to 4 & 12.

I have 4 & 12 and there is not enough space to put a grease nipple at the back.

I'm thinking though to put it on the inside, maybe about 10 o'clock as you look down on the pin. Then I should be able to access it without dismantling anything.

[bryanj]

I too did not see the original but did see the attachment, you could drill and tap for a grease nipple on the outsideas the bracket does not swing a large angle

[The Lone Builder]

I looked at that Bryan, but the fork leg covers the outside of the calliper.

The spare I have has shims top and bottom and is quite tight - maybe right is a better word - as it's not tight, just right 

I am just about to do it on the inside which I should be able to access through the spokes.

I ordered a selection of shims online so we'll see what happens.

Will let you know.