Zen and the Art of DIY Motorcycle Maintenance #03 …

Front Brake – What Front Brake? (Part 3)

Renovating Brake Calliper

A 40 year old Classic Honda Motorcycle. No road tax, no MOT, cheap to run, cheap to insure – an answer to the Cost Of Living Crisis?

What follows is a pictorial account with description of the 1st phase of that restoration – The missing Front Brake Part 3 …

Here’s the calliper cylinder with the corroded piston finally out, the accumulated sludge and corrosion clearly visible.
All the calliper castings before final clean
… And after cleaning

At this point I considered re-painting all the calliper parts while they were disassembled. To do this properly we (my brother and I) concluded the parts would have to go away to a specialist and as this project had a shoestring budget that was not an option. We also agreed that the ‘original’ look of the bike was important and there is a certain honesty and genuine appeal to the ‘weathered’ look of the callipers which matches the overall look of the bike as being loved but also well used. A shiny lacquered stove enamelled paint job would most definitely look out of place. Functionality was our prime concern.

So we needed a seal kit and first stop for classic Honda spares is David Silver Spares and a full list of available spares for the CB 250 RSA can be seen here. Unfortunately no brake calliper parts. Next stop E-bay and seller Powerhouse listed just the kit I needed.

Everything we needed – Result!
Here I am ready to go, another ‘pop up workstation’ location in the shade early evening.
The first seal fitted was the cylinder/piston seal seen here sitting nicely in its groove. The cylinder cleaned up ‘ok’ would love to have access to an ultrasonic cleaner (but that budget remember) so time and elbow grease it was.
Despite the awful appearance of the piston (see part 2 for images) it did clean up very well. Ideally a new piston but that was another £25 so not this time. Here is the piston back in the cylinder with new piston gaiter, all part of the Powerhouse kit. Note the damage to the piston by pipe grips/mole grips/vice … who knows? Not my brother or me, some previous owner? I removed the piston using ‘This Method‘ … 🙂
One of the two calliper slide bolts has this rubber sleeve which had perished and seemed to have swollen, there was no way it was going to slide back in, but a new sleeve was included in the Powerhouse kit.
Here’s a (poor quality – sorry) exploded view from the Haynes Manual … essential reference guide.
1 of 4 new sliding bolt gaiters
All 4 sliding bolt gaiters fitted (2 unseen at the back) and sliding calliper half assembled.
And here is the calliper assembled with new bleed nipple and new rubber bleed nipple cover.
And here is the calliper back on the bike, bled and ready to go.

End of Part 3.

Thank you for reading.

Recap Part 2 Part 1 Part 3 Part 4 Part 5 Part 6 Part 7

… And if you’ve just joined at Part 3, below is a little background to this story.

Motorcycling is in my blood [ RIP Dad – A Truly Great Father ] and because of motorcycles I’ve literally spilled many pints of blood [ Conscious Throughout ] My Dad passed the DNA and the bug to me in 1976 aged 15. My younger brother then aged 10 also caught the bug and eventually carried on the motorcycling tradition for far longer than myself. I rode on and off from age 15 to 40, all weathers, commuting on various ‘hack bikes’ while pampering and saving the main bike for dry (mainly) runs out for the sheer joy of riding. My brother recently bought a new 2023 Triumph 765 Street Triple R, a two wheeled sculpture if ever there was such a thing. The Street Triple was to join his stable of bikes alongside his classic Triumph Daytona 1200, and another classic, the Honda CB250 RSA you see below. The little Honda was his ‘hack bike’ back in the day, not used since 2010 and carefully stored, dry and covered in our Dad’s old garage. That garage is a shrine to our dear father, not really disturbed since his sad passing in 2016.

So the Street Triple needed room, the garage needs sorting but both my brother and I are dreading the day we have to disturb our Dad’s workshop and birthplace to so much of his woodwork creativity, and so many precious memories. The motorcycling bug never dies, although I myself have not ridden for over 20 years, the pull has always been there and watching the wonderful Allen Millyard‘s YouTube channel has fed my interest in the mean time, and when my brother suggested I take custody of his little classic Honda and get her back on the road I jumped at the chance!

… And Why ‘Zen’?

There’s a stand out section for me in the book Zen and the Art of Motorcycle Maintenance, and it is the part where the author describes making, or proposing to make makeshift ‘shims’ for his friends John and Sylvia Sutherland’s new and exclusively dealer serviced BMW motorcycle. Pirsig tries to explain how shims made from a discarded Coca-Cola can would be perfectly adequate and functionally identical to those fitted by the BMW Dealer’s mechanics at exorbitant costs. John Sutherland could not see this or be convinced, so programmed was he that only the main dealer has the expertise, equipment and materials to carry out such a task.

“In the book, the narrator describes the “romantic” approach to life of his friend, John Sutherland, who chooses not to learn how to maintain his expensive new motorcycle. John simply hopes for the best with his bike, and when problems do occur he often becomes frustrated and is forced to rely on professional mechanics to repair it. In contrast, the “classical” narrator has an older motorcycle which he is usually able to diagnose and repair himself through the use of rational problem-solving skills.”

Part 2 Part 1 Part 3 Part 4 Part 5 Part 6 Part 7

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Baffled Ape

Baffled by much of human behaviour, Life long engineer, Father, Mate, Love #Nature, #Engineering, Saved by #NHS, Stuck with #ChronicPain, Nature can provide #Green Clean #Energy #Politics is broken, we need #Sortition

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