Manual

[Stuckinmud15]

Hey does anyone have a link to the owners manual for an 81sh? Going to be working on the bike tonight and wanted to figure out how to properly install the calipers to remedy my brake sticking issue.

[ManitoulinLad]

Check out Catonic Bug's signature he has a link on it to his website to all the manuals etc. I did the brake thing your talking about last year its easy once you get the guidance from the manual & tips from teh website - Dan

[CatatonicBug]

The owner's manual doesn't cover that stuff. What you need is the Service Manual. I host both of those on my site (linked below), for a free download. Have fun!

[Stuckinmud15]

The owner's manual doesn't cover that stuff. What you need is the Service Manual. I host both of those on my site (linked below), for a free download. Have fun!

Hey I downloaded the after market service manual from your page, thanks. I however don't see any special way or method of re installing them...it just says to torque them to 32 ft lbs.

[cywelchjr]

Hey I downloaded the after market service manual from your page, thanks. I however don't see any special way or method of re installing them...it just says to torque them to 32 ft lbs.

Check out the factory manual, which does cover how to do it properly.

[Stuckinmud15]

Hey guys, I still am not seeing any special way of re-installing the calipers on my special in the factory or aftermarket service manuals. They both just basically just say to "replace caliper". I was looking on page 5-9 of factory service manual and all it says is "d. install the caliper assembly on the front fork" and below it is a diagram that shows what looks like a setup which doesn't look like mine. It doesn't say anything about the special model or anything like that.

[Incubus]

Are your brakes dragging? Did you remove the caliper piston and clean out the caliper? If so, try pulling your calipers, taking the top off the master cylinder and using big c-clamp vise grips to push the pistons all the way into the caliper. This let's the brakes reset and find their correct spacing.

First, remove the pistons and make sure the tunnel the pistons sit in are free of dirt and old crusty brake fluid.

Patrick

[Rasputin]

Both the FSM and Clymers have additional sections at the back of the books for the specials. Neither are great in describing what you are attempting, but page 230 in the Clymers is about the best description. There is a diagram or picture of the special setup on that page as well.

[Stuckinmud15]

Rasputin, thanks for referring me to that. I checked it out and it does say a couple things about the special model. It says to torque only 18 instead of 32 ft lbs and shows a diagram of how to reinstall the mounting hardware, and it looks like I'm missing an o-ring from that diagram. Will any old o-ring work? And is this the only special procedure I need to do?

[DGXSER]

When I mount my calipers on my Special, I get the bolt brought up snug, then I hold the brakes on (squeeze the brake lever tight) and then tighten the bolt up. My theory being that the caliper will be rotated to its operational location when I do so.

[crazy steve]

Rasputin, thanks for referring me to that. I checked it out and it does say a couple things about the special model. It says to torque only 18 instead of 32 ft lbs and shows a diagram of how to reinstall the mounting hardware, and it looks like I'm missing an o-ring from that diagram. Will any old o-ring work? And is this the only special procedure I need to do?

The critical adjustment is getting the rotors centered in the 'slots' in the fork legs. Torque the axle nut to spec, then loosen the two axle clamp nuts on the right fork leg. There's no adjustment for the left side, but on the right side move the fork leg until the rotor is centered in the slot, then torque the clamp nuts. Then install the calipers.

The missing o-ring is needed, but is nothing too special. It needs to be big enough to stick up out of it's groove by about .02-.03" so it's compressed slightly when the caliper bolt is tightened. This works as both an anti-rattle and as a seal to keep 'stuff' out of the pivot sleeve.