Recall a post in April, 2015 about a metallic "clank?"

[John Schmidt]

FOUND IT!  In the months following my first post I would periodically check things to try and pin it down. The noise made me a bit leery of taking any extended rides. I tried first swapping the springs on the shocks with no change, then swapping the shocks with an OEM set...no change. Not the exhaust hitting the swingarm although it was close to I installed a couple washers just for good measure. Tied up the kickstand to see if it was a weak spring letting it bounce...no joy. Then checked the same thing on the centerstand, again.....no change. A couple days ago I decided to remove the saddlebags and all the mounts and guard rails, then take a ride to see if I could narrow it down. The first bump would give a solid and loud clank, but then the noise seemed to dissipate somewhat. Strange! Then only one time on that ride as I approached a stop light the rough road caused it to really sound off and I just happened to apply the rear brake at the same time. The noise stopped. Bingo....just maybe I have it pinned down. When I got home and up on the centerstand, the picture below is what I found.

Rear caliper sitting with no pressure on it.


Here I'm pressing down on it, and if you pop it down with your fist you get the clank I was hearing. I ordered both the pin and the boot/bushing. Figured the pin has taken a beating so want to replace it. That's the first time I've ever seen that happen, what a PITA this has been.    Think I might replace that brake line as well, referring to the collar separation at the banjo bolt. I'll take a closer look for sure.

[salty1]

Glad you found it!     Any chance you can take a pic to add to this post of the old and new pins. This must be really rare.?

[John Schmidt]

Salty, I'll try to remember to take some pics when the parts come in. Figure end of next week at the earliest....and yes, very rare occurrence I'd say.

[Tfrank59]

Those are good pics – so what is missing in there some kind of a bushing or something?

[hubcapsc]

I guess it is #11, a rubber part... ?





-Mike

[John Schmidt]

Yep, Hubcap is right. For the time being I cut a piece of tubing to slip over that pin. Just big enough to fit inside the housing and around the pin. That way I can ride it until the parts come in, at least now I know what was clanking away.

[indybobm]

Good catch. The #12 pin in the fische is what you can remove with an open end wrench to remove the caliper without pulling the axle.

[Michvalk]

In thinking about what could have made that rubber fall out, something crossed my mind. Possible the bracket is broken, just behind the caliper? Just a thought

[hubcapsc]

In thinking about what could have made that rubber fall out, something crossed my mind. Possible the bracket is broken, just behind the caliper? Just a thought

I wonder if john removes his caliper from the backing plate instead of pulling
the whole thing... maybe mashing the caliper back onto the plate pushed the
rubber bushing out... ?

-Mike

[John Schmidt]

In thinking about what could have made that rubber fall out, something crossed my mind. Possible the bracket is broken, just behind the caliper? Just a thought

I wonder if john removes his caliper from the backing plate instead of pulling
the whole thing... maybe mashing the caliper back onto the plate pushed the
rubber bushing out... ?

-Mike

Mike, I don't remove the caliper itself, I pull the entire assembly when I pull the wheel. However, this time I'll just be removing the caliper since there's no need to pull the wheel for servicing just yet. When the parts come in, I'll probably also replace the rear brake line as well.....don't like surprises. I have a spare 45" SS line, just need to pick up a couple 35 degree bolts for the ends.

[larue]

Glad you found the culprit john

[Firefighter]

My 2000 IS sometimes clanks like that and it only does it once during a ride, will look at my bushing tomorrow. Thanks

[Michvalk]

Well, you'll have to remove the caliper from the bracket, I think. That rubber bushing is almost impossible to replace without having it out in the open. Has a little wide spot in the middle that sits in a groove in the caliper. At least you'll have to remove the bolt that goes through there, and I can't remember if that is a bolt, or a pin that is attached to the bracket. Hope that's all it is. I can't imagine Honda having a new bracket in stock.

[John Schmidt]

Mich, you're correct, it will involve removing the caliper....which will involve removing the hydraulic line. The pads are good, not many miles on them, but the line itself has quite few years/miles on it and the separation at the banjo concerns me. So, since I have to remove it I think it's a good time to replace it along with the pin which screws in and the boot for it. I'll do a little dismantling over the next few days so I can measure the length needed for a new SS line, plus have the caliper ready for the new parts later in the week. I'll try to remember to take a couple pics while I'm in there. 

[Ricky-D]

Well, you'll have to remove the caliper from the bracket, I think. That rubber bushing is almost impossible to replace without having it out in the open. Has a little wide spot in the middle that sits in a groove in the caliper. At least you'll have to remove the bolt that goes through there, and I can't remember if that is a bolt, or a pin that is attached to the bracket. Hope that's all it is. I can't imagine Honda having a new bracket in stock.

I don't see the rubber bushing you refer to listed in the OEM parts list.

***

[John Schmidt]

Well, you'll have to remove the caliper from the bracket, I think. That rubber bushing is almost impossible to replace without having it out in the open. Has a little wide spot in the middle that sits in a groove in the caliper. At least you'll have to remove the bolt that goes through there, and I can't remember if that is a bolt, or a pin that is attached to the bracket. Hope that's all it is. I can't imagine Honda having a new bracket in stock.

I don't see the rubber bushing you refer to listed in the OEM parts list.

***

Rick, it's #11 in the linked breakdown. The pin is #12, I've ordered both new....and a new line while in there. 

http://www.servicehondapsn.com/fiche_section_detail.asp?section=2552298&category=Motorcycles&make=Honda&year=1998&fveh=132668

[Ricky-D]

[/quote]
Rick, it's #11 in the linked breakdown. The pin is #12, I've ordered both new....and a new line while in there. 

http://www.servicehondapsn.com/fiche_section_detail.asp?section=2552298&category=Motorcycles&make=Honda&year=1998&fveh=132668
[/quote]
No, that's not it. That is the protector rubber for the pin (#10) which, if you look at any caliper, is very easy to distinguish.

***

[John Schmidt]

Nope, #13 goes on the pin you refer to, it goes between the caliper and the mounting bracket. The one I need(#11) goes through the bracket on the opposite side, pin #12 goes through it. I'll try to remember to post a picture of it when the parts come in.

[Ricky-D]

Nope, #13 goes on the pin you refer to, it goes between the caliper and the mounting bracket. The one I need(#11) goes through the bracket on the opposite side, pin #12 goes through it. I'll try to remember to post a picture of it when the parts come in.

You're correct. I was mistaken and confused with the numbering.  #11 and #12 are the items.

***

[John Schmidt]

Supposed to be here this Thursday, but the brake line probably not until Monday. Crap....was hoping to ride this weekend since the weather is supposed to be beautiful. Guess I'll work on the 1200 project, just got the last brake line needed for that today over at J&P Cycle in Daytona. What a madhouse that is right now. 

[John Schmidt]

Got the new pin and boot in today, new brake line should be here tomorrow...Friday. Here's a couple pics of the old and new. I had to remove the inside pad to allow the caliper to move outward enough to let the pin clear the mounting bracket, thereby letting me screw it in. Once in place and the front larger pin/bolt was in place, I reinstalled the pad. It's nice and solid now, just moves or "floats" as designed. Once I get the new line installed and bled out, I should be in business. One thing I noticed, the pin is about 7mm in diameter, the hole it goes through is about 12mm. Lots of room(~5mm) for the caliper to bang around on it. I also replaced the bleeder with a new Speed Bleeder. I have one on the clutch, now on the rear caliper, and a set on the bench for the front wheel. Weather is getting nice and I'm getting impatient. 

Compare these pics with the original, you'll see a major difference.

[Tfrank59]

So it looks like the pin was fine it's just the rubber bushing that's shot.  I wonder what mine looks like

[mark81]

great job john. I don't think this issue and repair could have been documented any better.