Brake Caliper Part Assistance Needed !

I have a 1982 Yamaha XJ650J Maxim that I cannot find a brake part for. My research on the part I need has reached the conclusion that this part was only in existence on the 1982-1983 models not the 1980-1981 model years. I have been trying to locate this part but those that have it require me to buy the entire brake caliper and I already have a spare one. The part could easily be made if I could only get the dimensions by tracing it onto a paper. The best way to indicate the part I need is for someone willing to help me to go to the diagram of a 1982-1983 front brake caliper assembly and at the very top is a wishbone -paperclip looking part with no part number and this is what I need. If you look at he 1980-1981 front brake caliper diagram this part is ommited. I dont think this part is necessary but would like to have it. I have posted wanting this part with no offers of any for sale so this is my only avenue. A picture of the part and a real sized tracing of the actual part could be of tremendous help ! I would be willing to pay a reasonable amount for the part or assistance in sending me a picture and tracing the part onto paper so I could duplicate it . I would also need the size of round stock it is made of ? PM me if you are willing to help !!!! THANKS TO ALL READING THIS POSTING ! DON

 

Check with Chacal. He may have what you seek. He has a parts list in the supporting vendor forum.

 

I see this is the second time you have posted this exact same question, so you must feel really hard up for it. But can you ask yourself the following question?

Are you sure you really need it? It may have been originally installed as a reduncancy measure, but found not to be needed, hence the reason no other models or years have it.

What is happening with your bike, that makes you feel you have to have that part?

 

It's used on all 80-83 XJ650 Maxim/Midnight Maxim models, as well as on the XJ1100 rear caliper (which is a mirror opposite caliper design from the 650 Maxim front caliper). It's used to shim the caliper away from the fork tube mounting boss and allow the caliper to rotate and orient itself properly, as well as preventing the caliper fromt rattling about. I would hesitate to omit it from your brake system; the factory used it for a reason.

It's hard to find people that are selling it as part of the "caliper" because it really doesn't attach to the caliper itself; it clips onto the fork tube mounting boss flange that the caliper attaches against. You may have more luck inquiring with people who have used forks for sale, as this shim normally remains on the fork tube when the caliper is removed.

 

Perhaps we aren't thinking of the same part then. The part I am looking at looks like a spring device that acts as an anti-rattle feature for the retaining clip for the brake pads.

 

On some models, the factory also included a brake line junction that many of us have seen fit to chuck in the trash can with no ill effects.

 

There's one of those in there, too. The caliper-to-fork tube shim is improperly placed in the diagram, it makes it appear to be located somewhere "within" the caliper pad well, but it really isn't.

The elimination of the union joint won't cause the system to fail, but it will provide a spongier lever feel. The rubber brake lines swell under pressure (and the harder and quicker the pressure rise, the greater the swell). The banjo fitting "necks" and the union joints, being made of metal pipe, eliminate some amount of "soft" rubber hose in favor of a hard metal pipe.

 

We are not looking at the same drawing then. I am drawing no correlation between what you are talking about and what I am looking at.

The brake lines I replaced my OEM brake lines with are not rubber. They are a semi-hard tube surrounded by rubber. They don't swell and they my brakes aren't spongy.

 

I really don't understand why no one seems to understand the part I am searching for. The diagrams of the front brake caliper on a 1980 nd 1981 don't show the part I need but the diagram for a 1982 and 1983 show this part. The part on the diagram has no number and according to dealers I have spoken to is because it is considered a part of the caliper. The part is not internal to the caliper but external it fits between the fork and the caliper and has tabs on it that hold the top of the pads in place. I originally had the piece but for some reason have misplaced it so I know it exists. I won't bother any of you with future posts on this subject. It is evident that I have been a pain in the butt !!!

 

Illinoisxj650, Negative ghostrider. You have not been a PITA!
I've looked up your part as you describe and, while I don't have one, I'm sure one of our members does. Chacal isn't a slouch when it comes to parts and I would coordinate with him to see if he has one and can hook you up with a rough sketch. It might be that the original factory manual has some reference to it that might be a bit better than BikeBandit.com's fuzzy picture. Don't give up hope, just try to explain what you need in a different way. Best of luck on finding the information you seek.

 

Don...........I've sent you a PM.

 

I see the part you're talking about. It looks like a clip that either holds the caliper sleeve in place, or spreads the pads, or a bit of both.

I looked at a number of parts diagrams, including the XJ1100J rear caliper, but I didn't anything like this part other than on the 650 Maxim.

One interesting thing I did notice was that, while the caliper looks the same on the '82 Virago 750, it doesn't show that clip in the diagram either.

 

I have atempted to atach the diagram of the front caliper of a 1982 XJ650j. Which item are we looking for? The only piece without a discription number if just above number 8. it looks to be a tension spring.

 

#5 ?

 

I also don't think you have been a bother, I just thought it was odd that you thought you were going to get another answer by asking the same question from the same group of people on a different day.

At first, I thought you were another poster, and I was going to refer you to the other thread for an answer. Then I realized you were the same person.

Polock, that drawing does not show the part that I believe the OP is asking about.

 

No, it's not shown in this diagram.

If you look at the one on kawasakipartsnation.com for an '82 XJ650J, you'll see a bent wire clip/spring that attaches on top of #6.

 

The un-numbered part is what is being discussed, I believe.

 

In the assembled position

 

I believe you're right, and that tension clip or wire seems to hook into the #15 shim spacer or caliper anti-rattle clip (#15 is termed a "caliper retainer" in the parts diagram).

The #15 caliper retainer actually attached to the bottom of the fork tube protrusion via tension clips or lips.

I've never seen that triangular clip on any of the many calipers (or fork tubes) that we've had, and it's not shown or noted in the '82-3 service manual procedures, either..........so I'm at a complete loss!

 

I think #14 is the anti-rattle clip, and #15 is actually a retainer for the top portion of the brake pads. As you can see in the pics, only the lower portion has the large retaining pin going through it, so the top would still need to be supported so that the pads wouldn't attempt to rotate out of the caliper, and that is how it is done.

And as I mentioned earlier, I think it is a redundant feature that was later dropped from the assembly.

Personally, if the part really needs to be there, I would make one out of a wire coat hanger. Maybe even one of those really large paper clips.

 

[quote="Broke_Dirty_Maxim]And as I mentioned earlier, I think it is a redundant feature that was later dropped from the assembly.

Personally, if the part really needs to be there, I would make one out of a wire coat hanger. Maybe even one of those really large paper clips.[/quote]

While it does seem odd that it was used only on some models, I don't know about the "later dropped" part of the theory here. Reason being that it was NOT used on 80 and 81, but was used on 82 and 83. It's also odd that 82 650 Maxims had it, but 82 750 Viragos, with almost exactly the same caliper, did not.

As for making one, I think the problem is that he doesn't have a pattern to copy. That was part of the original appeal of this thread, in case someone else has one that could be measured, photographed, traced, etc. If you do decide to just try making one, I'd recommend going to Ace hardware and picking up a couple of pieces of piano wire. They are much better for springs than a hanger would be.

Cheers,
Paul

 

While it does seem odd that it was used only on some models, I don't know about the "later dropped" part of the theory here. Reason being that it was NOT used on 80 and 81, but was used on 82 and 83. It's also odd that 82 650 Maxims had it, but 82 750 Viragos, with almost exactly the same caliper, did not.

As for making one, I think the problem is that he doesn't have a pattern to copy. That was part of the original appeal of this thread, in case someone else has one that could be measured, photographed, traced, etc. If you do decide to just try making one, I'd recommend going to Ace hardware and picking up a couple of pieces of piano wire. They are much better for springs than a hanger would be.

Cheers,
Paul[/quote]

I still think it was dropped just like the YICS was. Someone had an idea, it was determined it was redundant or useless, so it was dropped.

If I made one, it would only serve to retain that retainer in place. I wouldn't care about the springiness. And you don't need a template for that. Wrap it around the bolt, and make sure the ends go into the holes on the retainer. Done.

 

As far as I can tell, they had this clip in '82 and '83... in '84, they didn't just drop the clip, they dropped the whole bike - at least from US import.

 

Broke_Dirty_Maxim the diagram with the circled part is the one I was worrying about. The reason I was so persistent about it was because I was concerned about not having it installed on the brake caliper could create a safety issue ? I have completely restored my 1982 X650J Maxim and while puttin it back together noticed the part appeared to be missing and thought I must have lost it. I think I remember removiing it from the caliper when I disassembled the brake system. Cold this part be solely for the XJ650J Maxim ? I wouldn't think the part would be a necessity seeing how many clipers are without it . THANKS FOR ALL YOUR PATIENCE AND CHACAL FOR HIS VALUABLE SERVICE. DON

 

Any original owners out there with one still fitted?

I LOOOVE Yamaha parts mysteries. Here's yet another, like the shims that are supposedly under the plates on some calipers but nobody's ever seen one, or 550 Seca rear sprockets.

Is this something everybody lost when they took one apart, like the oil filter spring washer?

Chacal?

 

Wow! That's off topic but very interesting.

On both of my bikes, the first time I changed the oil filter I found that washer to be missing. I fabbed replacement washers for them by cutting down and drilling out washers I had on hand. Are you suggesting that that washer might not actually have been installed in the first place, even though it's on the parts diagrams?

 

no, I was saying that it's something that usually got lost the first time anyone had it apart.

At least THAT washer is in the fiche.