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Buell Forum » Old School Buell » Archive through November 11, 2014 » S2T front brake caliper-center bolt with spacer-stripped « Previous Next »

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Two_seasons
Posted on Friday, October 10, 2014 - 09:31 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Well guys, I'm finally getting my S2T back together.

Unfortunately, I followed the torque spec in the FSM for the front brake caliper center bolt, the one with the spacer. It called out 28 ft. lbs.! I should have known better (probably should have had another coffee). I stripped out the aluminum threads in the caliper.

I went over to the hardware store and found another SAE 1/4-20 with a 3/16 allen head but, the bolt has a longer shoulder than the OEM bolt. I'm thinking that if I can get it threaded deeper and a little longer so it pops out the back, then use a nylok nut on the backside?

Any suggestions are appreciated. I was also thinking about a time-sert but have never used one.

TIA
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Ratbuell
Posted on Friday, October 10, 2014 - 10:53 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Hm.

I could swear mine says in-lbs.

Regardless...simply drill the threaded (ex-threaded) side out big enough to let the shoulder pass through, but not big enough that the spacer passes through.

Definitely use touchup paint dots as a quick reference once you torque everything - brakes get hot, nylocks lock using nylon. It can melt. Either that, or get a star washer and regular nut (still use the paint dots though!).
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Sportyeric
Posted on Friday, October 10, 2014 - 11:27 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

My first go around at mechanic-ing on the Sportster, I saw 90 ft lbs for the torque on the exhaust nuts. (I stopped, too late, at about 50 ft-lbs) Now I know about inch-pounds.
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Harleyelf
Posted on Saturday, October 11, 2014 - 12:29 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I'd stay away from nylock nuts for a high heat, safety related application. Can you install a heli-coil in the hub? That's what I did when my S3 stripped a rotor mounting bolt.
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Two_seasons
Posted on Saturday, October 11, 2014 - 07:09 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ratbuell, do you mean using touch-up paint dots to check for any rotation of the bolt once installed? Or as a reference to monitoring heat? I'm going to hold off drilling anything until I know what plan B looks like.

By the way, I was commenting to my lovely wife about Erik and the elves clever use of AL for the caliper. So light and pretty!

Sportyeric, yeah, like I said, tired and not thinking. The caliper mounting bolts to the fork calls out 23 ft. lbs. and the bolt is at least 5x bigger than that center bolt with the spacer

Harleyelf, like you, wasn't comfortable with nylon used for this application. Back up was the two adjacent pins that use the cotter pins Regarding the helicoil, maybe that or a time sert.

Page 2-22 in the 95/96 S2(T) FSM calls out 28 ft. lbs.. Not the first time I've come across an error in a motorcycle FSM. Kawasaki did it to me when re-installing cam bolts in my Z1-B. Used a helicoil for that application. I was fearless, invincible back then

I'll keep you guys posted on plan B. Thanks for your thoughts. BadWeb rocks!
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Ratbuell
Posted on Saturday, October 11, 2014 - 10:08 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Paint is for a rotation indicator - I do ALL my critical fasteners, anytime I touch one. Axles, pinch bolts, caliper mounts, rotor mounts, fork clamps, steering head, case covers, you name it. My bike looks like it has acne...but my preflight checks last seconds not minutes, and nothing shakes loose : )
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Dannybuell
Posted on Saturday, October 11, 2014 - 10:11 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I had a helicoil put in on my 96S1's caliper about 15 years ago. No 'weird tweaks' and No problems.
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Two_seasons
Posted on Saturday, October 11, 2014 - 01:26 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

OK, so here's my current situation.

I've found my Helicoil kit in my toolbox from the above mentioned problem I had with the Z1-B. And, get this, it's a 1/4-20 kit! Only one issue, I don't have the 17/64 bit or the correct tap. So...off to the hardware store I go.

Wish me luck. My goal is to get this crate on the road within the next two days and go before it gets any colder. This am...32 degrees F
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Court
Posted on Saturday, October 11, 2014 - 03:13 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Face it . . you are in Wisconsin . . the 17 days of summer have passed.

:-)
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Two_seasons
Posted on Saturday, October 11, 2014 - 05:55 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

OK, Plan B, the Helicoil fix worked .

Just for historical purposes when another BadWebber passes by this way, here is what was used to fix the stripped out front caliper center bolt with the spacer (apparently used as an anti-rattle fix for the brake pads)

Size Bit Used = 17/64
Size Tap Used = 5/16 coarse thread
OEM screw used = 1/4-20 with a 3/8" shoulder between the inside of the bolt head to the start of the threads and 2" length from bolt head to end of thread

I am elated! And I'm making coffee so I pay attention this time...plus I corrected the FSM to read 28 in. lbs. By the way, that info is located at page 2-22 if you're interested.

Thanks everybody.

BTW Court, I'm putting in a SpaceRay garage heater (made in Charlotte NC USA baby) to make those summer days last longer, at least for maintenance
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Harleyelf
Posted on Saturday, October 11, 2014 - 07:31 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

You mean it gets colder? I just moved here (Appleton, WI) in July and my new employer assured me I could ride to work year-round.

They wouldn't lie just to get me to leave Florida, would they?
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S1owner
Posted on Saturday, October 11, 2014 - 08:16 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Yes they would lie you get 4 months of riding and 8 months of misery!!!!!!!!
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Ratbuell
Posted on Saturday, October 11, 2014 - 09:36 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The center pin is MUCH more than an anti-rattle - that's what the bent-metal clips/springs are for. The center pin keeps the caliper from flexing.

When I got my S2, it was missing that bolt/spacer. It stopped...just took some more squeeze on the lever, but I made do. Then, I checked out a friend's S2 - hey....what's this bolt?? Went to the garage shelf to a spare caliper I had (later style, 97 S1 I believe - embossed pegasus, not engraved). Lo and behold - bolt and spacer.

Put it in and HOLY CRAP the brakes work a lot better!!! That one bolt? Makes a HUGE difference!!
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Harleyelf
Posted on Sunday, October 12, 2014 - 03:02 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Had four months of riding weather already, plan to use the '66 Microbus from Nov 1 to April 1 - have already bought it new heater boxes and shall install helper fans.

Love the new job! Bought the S3 back from the guy I sold it to in March and really enjoy the local roads.
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Two_seasons
Posted on Sunday, October 12, 2014 - 04:45 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Harleyelf, we still may have another 6 weeks worth of riding.

The roads up around Elkhart Lake are pretty good too. But watch out for the FDL Sheriff that hangs out on Hwy 67, Long Lake area, in the town of Dundee.

There are other speed traps up there, so be careful.
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Harleyelf
Posted on Sunday, October 12, 2014 - 05:23 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Good to know. Got disoriented on the way home from Neenah yesterday and spent a lot of time on some Lake Shore street. Saw speed bumps but no Sheriff cars. Haven't registered or insured the S3 yet, still using the custom. It has no speedometer but doesn't corner worth squat so I don't push it.

Will PM you when I'm ready to see the secret roads only the locals know about.
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Two_seasons
Posted on Sunday, October 12, 2014 - 07:25 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Sent you a PM.
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Harleyelf
Posted on Sunday, October 12, 2014 - 09:48 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Got it, thanks
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