Zen and the Art of DIY Motorcycle Maintenance #06 …

Rear Brake Adjust …

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? Maybe, but more importantly for me, a mindful escape into hands on problem solving and rejuvenating old skills.

What follows is a pictorial account with description of the progress of that restoration – Part 6 Rear Brake Adjustment …

Every motorcycle I’ve ridden since I came to grief on a bike in 1979 has required an adjustment to the rear brake pedal to compensate for my resulting ‘drop foot’.

Because of the medical condition I mention above, I need to have the rear brake pedal set a lot lower than standard. This has always been achievable with a few tweaks to the existing adjustment points. In the diagram above, the height of the rear brake pedal (1) is set by adjusting bolt (6) and locknut (5). However the standard bolt (6) is not long enough to achieve my desired pedal height, so I substitute for a longer bolt. Also to achieve the necessary lowering of the pedal I remove the brake pedal and turn it clockwise by one increment on its splined shaft (9) See actual images below …
To remove the lever, this clamping bolt has to be fully removed as it sits in a groove on the shaft (see 9 on the diagram above)
Here is the actual rear brake lever pivot having been removed and turned clockwise by one increment on its splined shaft. You can see the dot on the shaft and the dot on the lever are now not aligned as they were when the bike left the factory.
Here I have removed the original adjusting bolt and locknut which is too short to achieve the lower pedal I require.
Does anybody remember these small tins of Golden Virginia rolling tobacco? Back in the day my Father would roll his own cigarettes or ‘roll-ups’, these little tins were (and still are) very useful for storing bits and bobs. I think this tin and its contents must be at least 45 years old! This tin and another like it have sat in my tool shed wherever I have lived, and these tins were the first place I looked to see if I had anything suitable to use as an extended brake pedal stop/adjusting bolt.
… And I found just the thing, a countersunk, socket headed high tensile setscrew about 10mm longer than the original bolt.
Having set the pedal at the desired/lower hight using the new stop screw, my attention now turned to re-adjusting the actual brake operation as my changes at the pedal/lever had upset the setting. The rear brake operating arm (12) is adjusted by the special nut/cam seen below …
The rear brake adjuster nut/cam
So, while adjusting the brake I noticed movement of the brake operating arm on its splined shaft, but when attempting to tighten the clamp bolt it was apparent that something was not right … (see below)
And here’s the clamp bolt & nut removed showing stripped bolt thread
So another rummage through the tobacco tin of useful bits and bobs produced a perfect length stainless steel cap screw, washer and nut – result!
And here it is fitted and tightened – job done!

The last step is to re-adjust the rear brake light switch. For some reason I forgot to take a picture of said switch and there is no image/diagram in the Haynes Manual. At some point, for continuity I will take a picture and edit this post.

While working under the bike on the rear brake etc, I noticed a missing exhaust clamp bolt. So another rummage through the ancient tobacco tin produced a perfect stainless steel bolt/washer and nylon nut (see below)
Another little job done and working towards this old bike’s first MOT test in 12 years … fingers crossed.

End of Part 6.

Thank you for reading.

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

… And if you’ve just joined at Part 6, 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.”

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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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