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350TSS · 04-03-2020, 05:39 PM

Today I made some progress although I am waiting for some specialist bolts to absolutely be sure that I have solved my rear caliper/disc lateral positioning/brake hanger interface issue.
At the start of the morning the disc was attached to the wheel boss sitting on spacers 10mm thick, if the caliper was through bolted to the hanger on the outside of the hanger, the centre-line of the disc was c 8 to 9 mm outboard of the centre-line of the caliper. Easy I thought, just spacer the disc off the wheel by the requisite distance.
When I got the wheel out I was not comfortable with that solution as the aluminium wheel boss to which the disc is attached only has about 15 mm of thread depth and there would be circa 18 to 20mm of spacer between the disc and the wheel boss which is quite a lot of leverage for an 8 mm aluminium thread.
I decided instead to bolt the caliper to the to the inside of the brake hanger with the bolts threading outwards. The downsides are that a) the bolts will have to be countersunk otherwise the heads will hit the disc, b) obviously I will also have to countersink the two attachment bolt holes on the inner face of the caliper casting mounting lugs and c) from a maintenance perspective caliper removal can only be possible by removing the rear wheel. Upside is that all the spacers between the wheel hub and the disc can be dispensed with and the 6 x steel bolts can all be 20mm shorter so overall a lighter solution. The disc attachment bolts have to be steel to trigger the magnetic speedometer sensor.

Next I decided to modify my tool tray as I think with the ride height adjusters in place there is a slight danger the suspension rocker will hit it at or near to full bump. This involved cutting a section out of the leading edge, making a 1mm polypropylene mould then laying up 3 laminations of CF.

Finally, I set about fitting the clutch hydraulic pipe and finding a suitable route for it. Annoyingly the original pipe is about 40 to 50mm too long, not surprising since I am using clip on handlebars. Tomorrow I will try to determine the lengths for the 2 x front and 1 x rear brake hoses (and the angles for the union eyes on each end and will then get them all made up) HEL, Venhills, Goodridge - any recommendations???

04-03-2020, 05:39 PM	#1171
350TSS Too much time on my hands member Join Date: Jan 2013 Location: Shipbourne Bike: M900 Posts: 1,419	Today I made some progress although I am waiting for some specialist bolts to absolutely be sure that I have solved my rear caliper/disc lateral positioning/brake hanger interface issue. At the start of the morning the disc was attached to the wheel boss sitting on spacers 10mm thick, if the caliper was through bolted to the hanger on the outside of the hanger, the centre-line of the disc was c 8 to 9 mm outboard of the centre-line of the caliper. Easy I thought, just spacer the disc off the wheel by the requisite distance. When I got the wheel out I was not comfortable with that solution as the aluminium wheel boss to which the disc is attached only has about 15 mm of thread depth and there would be circa 18 to 20mm of spacer between the disc and the wheel boss which is quite a lot of leverage for an 8 mm aluminium thread. I decided instead to bolt the caliper to the to the inside of the brake hanger with the bolts threading outwards. The downsides are that a) the bolts will have to be countersunk otherwise the heads will hit the disc, b) obviously I will also have to countersink the two attachment bolt holes on the inner face of the caliper casting mounting lugs and c) from a maintenance perspective caliper removal can only be possible by removing the rear wheel. Upside is that all the spacers between the wheel hub and the disc can be dispensed with and the 6 x steel bolts can all be 20mm shorter so overall a lighter solution. The disc attachment bolts have to be steel to trigger the magnetic speedometer sensor. Next I decided to modify my tool tray as I think with the ride height adjusters in place there is a slight danger the suspension rocker will hit it at or near to full bump. This involved cutting a section out of the leading edge, making a 1mm polypropylene mould then laying up 3 laminations of CF. Finally, I set about fitting the clutch hydraulic pipe and finding a suitable route for it. Annoyingly the original pipe is about 40 to 50mm too long, not surprising since I am using clip on handlebars. Tomorrow I will try to determine the lengths for the 2 x front and 1 x rear brake hoses (and the angles for the union eyes on each end and will then get them all made up) HEL, Venhills, Goodridge - any recommendations???