Crush washers for front brakes (and master cylinder)

[Raux]

That's a wheel to rotor offset deal.

The OP never stated anything about SBK wheels.

nothing to do with the calipers/forks.

sure if he's using 749 forks then the brake mounts are 5mm too far out

[Raux]

the calipers and their mounts are the same. but the spacing on the fork lowers' caliper mounts are different.

here from the front


Fork - Caliper - Wheel - Caliper - Fork
Fork - Rotor -   Wheel -   Rotor - Fork

for the 749s it would be 10mm wider at the rotor so the caliper mounts on those forks would be 5mm on each side further away from the wheel

since you used the s4r forks your calipers lined up fine

[Raux]

here's a test

take the calipers off their mounts. just hold them both on the rotors and squeeze the lever

if you have firm lever then your mounts are the problem.

[yosso]

were the thickness of the wood and rotors the same? are your rotors 4mm thick?

and you have no leaks? two quarts and a pint?

Wood thinner than the rotor, rotor "mic's" out at 5.76mm.

I've had issues with the crush washers, but I _think_ that I've got that all settled.  I've yet to check the MC, but I've got a shortned 10mm bolt, but I need to run to town to get a tap to dress the threads before installing.

I'm going to get a MC rebuild kit from bevelheaven.com this week and then mess around next weekend rebuilding the MC, but after getting a firm lever while using the shims, it seems like my problems lie elswhere.

Pictures (3mm spacers)




Pictures (5 mm spacers)

[yosso]

here's a test

take the calipers off their mounts. just hold them both on the rotors and squeeze the lever

if you have firm lever then your mounts are the problem.

Bingo, we have a winner.

I just removed the bolts from the left caliper, just sitting on the rotor.  Two squeezes and it's tight.  So it's the mounting of the calipers.  My spacers are made up of a bushing and a washer, which together measure 5mm (or 4.99 mm).

Does somebody sell the spacers or do I need to visit a local machine shop?

Sigh, at least I'm making some progress. 


Mike

[Raux]

rotors should be in the same place.  

-10mm narrower rotor mounting on the wheel = 2x +5mm offset rotors.

the 749s rotors are 15mm offset rotors. the fork mounts are where this shows up at. not the wheels.
if you measure the 749 rotors from the left to right you would get say 300mm wide looking at it from the front
if you measure a monster it would be 290mm wide
the fork mounts for the calipers (same calipers) are 5mm further away from the wheel on the 749 forks.
the 749 and monster forks are the same distance apart
so the difference is the mount on the forks for the calipers

he needs to move his calipers 5mm further in towards the wheel on both sides

[DarkStaR]

...

for the 749s it would be 10mm wider at the rotor so the caliper mounts on those forks would be 5mm on each side further away from the wheel

since you used the s4r forks your calipers lined up fine

Ok, I think I got it now.  I was looking at it from wrong the wrong direction, and was totally disregarding the forks mounts being different.

Good to know.

I've modified/deleted some of my previous posts to not confuse people in the future.

[yosso]

the 749s rotors are 15mm offset rotors. the fork mounts are where this shows up at. not the wheels.
if you measure the 749 rotors from the left to right you would get say 300mm wide looking at it from the front
if you measure a monster it would be 290mm wide
the fork mounts for the calipers (same calipers) are 5mm further away from the wheel on the 749 forks.
the 749 and monster forks are the same distance apart
so the difference is the mount on the forks for the calipers

he needs to move his calipers 5mm further in towards the wheel on both sides

I just tried it with the calipers bolted in place w/5mm spacers (as good as I can get with sandpaper) and if the bolts are not tightened then I get a firm lever, once the bolts are tightened, then the lever is no longer firm.  Which is telilng me that my spacers are not close enough to the same size or something.

Sigh, it never ends.   

[Raux]

well you've now got a firm grasp of the singular problem you are having.

pm Duckstew to see if he has the spacers you need.

[yosso]

well you've now got a firm grasp of the singular problem you are having.

pm Duckstew to see if he has the spacers you need.

Thanks, appreciate the help and contact.  What's one more week or two after waiting all summer. 

Have a great evening.

Mike