Front caliper part missing during rebuild... Ideas?

Hey Everybody!

So, I decided to do some pretty intense maintenance (for me anyways) to my bike recently and i've run into a slight problem. I changed out the clutch friction plates, oil, final gear oil, spark plugs, gauge cluster bulbs for LEDs, and am completely rebuilding the front brakes.

The front brakes are where i have the problem. Everything is being either rebuilt or replaced. In the course of pulling the front caliper and the master cylinder off i decided to get them sand blasted and powder coated so they looked nice and i wouldn't miss anything during the cleaning. I've got everything back now and have rebuilt both, but when i went to put the caliper back on i noticed a problem The diagram in my manual shows a "plate washer" (part 90201-08689-00) on the top of the caliper as well as below between the main bolt and sleeve. When i took the caliper off i was very careful not to misplace everything, and know the part was not lost. It was missing from who knows how long ago, which explains some of my brake issues. My questions is: Are those plate washers the same? They have different part numbers in the catalog, and apparently are not available. If they are different, what is the difference? I'm planning on going by the hardware store tomorrow and matching the washer underneath to use as the top washer, but i have a lingering suspicion that the top washer may be thicker than the bottom one. Any help here would be greatly appreciated! I've gone through a lot of trouble to make the front brake operate smooth and well. Props go to Chacal for the awesome replacement looking glass for the fluid in the master cylinder!

Thanks everybody!

 

I am assuming that when you disassembled the bike that you placed the washers, and nut onto the bolt for the caliper. In which case the washer you reference should be the same size as the lock/spring washer (M8). Take the mounting bolt with you to make sure the washer will fit over the threaded end.

As far as the thickness of the washer is concerned. It should not matter. It is a bolt/nut combiination, and the plate washer is there to keep the lock/spring washer from digging into the soft aluminum body of caliper, and to keep the sleeve from sliding out of the caliper

Most hardware stores generally carry a mixed supply in the bulk bins. You can sort through, and usually find different thickness washers. Also If the hardware store has the slide tray style assortments. There will sometimes be different thickness washers available that way. If you want to dress it up a bit. You could always go with chrome washers. I know that these are available at ACE hardware stores now.

Ghost

 

The washer between the caliper and mount point is quite thick, almost a spacer rather than a washer. Without it the caliper will be in the wrong position. The one under the head of the bolt is just a washer.

My 650 max was missing it when I got the bike. I put in a stack of fender washers but don't remember how I cam up with the correct height. I might have just eyeballed it.

Maybe some kind soul on here will measure one so you know what you need.

 

Hey Micarl - that's the one! I was operating this bike without that washer and having a lot of front brake problems. If anyone would be kind enough to take a thickness measurement of that spacer/washer I'd be very greatful!

Thanks for your guys help!

 

HCP3492 OEM caliper pivot bolt FLAT WASHER
oem # 90201-08689-00
caliper-to-fork tube, upper (on top of caliper)
20.0mm OD (.7874")
9.00mm ID (.3543")
3.15mm thick (.1240")

We should have a good used one available..........