Topic: All Balls Racing Caliper Rebuild Product ('77 CB550F)

[GardenGnome]

Hello again, I'm making some good progress on my rebuild. Yesterday I rebuilt the forks, and by rebuilt I mean I put in new fork seals and fork oil. Let me tell you, and as probably many of you know those little buggers are tough to get out. I ended up breaking a chisel in my attempt (nothing was marred or damaged to the forks). Anyway I'm waiting for a new Cam Chain Tensioner to arrive and in the mean time I thought I'd tackle some smaller bits to my project.

So I have the rebuild kit for the front caliper from All Balls Racing. I am a bit confused what the two copper washers and two thin o-rings are for? I didn't see any of those bits when I was disassembling it. Not sure if I missed something or if it just didn't have it to begin with? Does any one with experience with the All Balls product for this application have any input? This is my first time using their stuff.

[slikwilli420]

Copper washers are for the damper rod bolts.

[GardenGnome]

Copper washers are for the damper rod bolts.

Based on the image here, the copper washers and o rings go where? https://images.cmsnl.com/img/partslists/honda-cb550-super-sport-550-four-cb550f2-1977-usa-front-brake-caliper_bighu0048f0208_e8c9.gif

[Stev-o]

Let me tell you, and as probably many of you know those little buggers are tough to get out.

A little late now but I use a small C-clamp to extract the fork seal, fairly simple.

[GardenGnome]

There are copper washers beneath the drain screw (lower leg, outside) and beneath the axle clamp to hold the damper rod. Both are “crush washers” to prevent leaks and over torque of the screws.

I am so sorry. I just have no clue what and where the drain screw and axle clamp are. I've looked at the documents section here on the site and I couldn't find boo.

[Bodi]

What AB calls a caliper rebuild kit is, in fact, a master cylinder rebuild kit. The O-rings and cup seal go on the piston shaft. The crush washers are for the banjo.

[GardenGnome]

What AB calls a caliper rebuild kit is, in fact, a master cylinder rebuild kit. The O-rings and cup seal go on the piston shaft. The crush washers are for the banjo.

 That's helpful to know. So far the only piece I have figured out is in fact the cup seal for the piston. Still have two little o-rings and the copper washers left in the kit. I was thinking of making my own brake lines, since the ones I pulled off were cracked and gross.

In regards to the o-rings and copper washers, where in terms of the link I provided would those go?

[Stev-o]

Many of us buy stainless brake lines from member Shaun, very reasonable. He gives us a SOHC4 discount...

http://www.slingshotcycles.com/

[GardenGnome]

There are copper washers beneath the drain screw (lower leg, outside) and beneath the axle clamp to hold the damper rod. Both are “crush washers” to prevent leaks and over torque of the screws.

I am so sorry. I just have no clue what and where the drain screw and axle clamp are. I've looked at the documents section here on the site and I couldn't find boo.

sorry, saw "forks" in your post and flaked. This comment above was about the fork washers, not caliper *forehead smack*

Heh it's all good, I just wanted to share with everyone where I'm at with the project rebuild. I did decide to pull the motor again and am currently waiting for a replacement can chain tensioner. The one that was in there just didn't sit well with me. It wouldn't spring back and there was some wear on it. I'll post a pic when I get it out and compare to the new one.