Next in line was the rear brake assembly. As the K doesn't have linked brakes, I'm not forced to do the whole braking system at once.
Starting with laying everything out for the system ...
... everything looks good, but dirty, except a rubber boot on one of the pistons in the rear caliper but just touching this caused it to return to it's seat, so no major issues there.
The caliper had the pins drifted out with a punch ...
... to allow the removal of the pads and rubber boots, the caliper was in good working order, the strip down didn't go any further.
The bleed nipple was removed and bolts popped into the open brake fluid channels, before the caliper was cleaned up with Muc-Off motorcycle cleaner before being remounted on the bike and the original grease nipple replaced ...
... the fittings will be replaced once the paint work on the system is complete.
Next was the ABS sensor, the bracket of which had suffered a little from exposure to brake dust which was rubbed down and masked up. the masking covered the base of the internal side of the bracket to ensure the same clearance on the ABS sensor as before hand and avoiding any shimming up.
The bracket was given a couple of coats of Halfords Black Engine Enamel, as there will be some heat exposure ...
... before being mounted back onto the rear caliper and torqued up to the setting in the Haynes Manual.
The sensor itself was cleaned up and the original shims used (again to preserve the original clearance) and mounted into the bracket.
The gap was measured with feeler gauges and found to be 0.4 mm, well within the 0.35 to 0.65 mm range stated, that's sorted then!
The next item to strip off and sort out are the brake fluid lines. These had the ends cleaned up with a wire wheel attachment to remove the road crud and surface corrosion build up, before 2 M10 bolts were used per line, as well as the original copper washers, to ensure no paint got in the area it would meet brake fluid in the future ...
... before being masked up and given 2 coats of MOTIP Silver Brake Caliper Spray before being de-masked ...
... and allowed to cure.
While I was doing that, I got to work on the ABS bracket and the bottom half of the battery box by cleaning up the battery box to find it was in quite good shape, so nothing really needed there, before treating the ABS mounting bracket to a wire brush drill attachment, Autoteck Etch Primer, Halfords Gloss Black Enamel and Halfords Clear Enamel Lacquer.
Once everything was cured the battery box was bolted back onto the ABS bracket, using cleaned up fittings and new nuts/washers ...
... before being bolted back onto the top of the gearbox so the basis of the reassembly was ready.
The master cylinder, reservoir and connecting hose were in good shape and fully functional so it was just cleaned up with Muc-Off motorcycle cleaner before being fitted to the back of the right hand footrest, using the original bolts (which were in good condition) ...
... and bolted to the bike meaning the first part of the system is reinstated.
Next on the component list was the ABS pump for the rear brake, which showed both surface corrosion and had paint flaking off ...
... so the areas with corrosion were stripped back to bare metal to ensure I got rid of it before the rest of the paintwork was rubbed back with a scotch pad to allow the new paint to key followed by a tac-clothing all over.
The pump was then masked up and given coats of Autotek Etch Primer, Halfords Gloss Black Enamel and Halfords Clear Enamel Lacquer allowing a cure between coats and a good long cure after painting was complete.
The ABS system was loosely bolted together...
... to identify what was needed, allowing stainless bleed nipples, banjo bolts and copper washers to be ordered. Also, this allowed me to check hose routing to make sure nothing was fouling.
Next was the rear brake lever assembly, for which all of the bits were pulled together...
... these bits were disassembled and the old bits all laid out with replacement pieces added to match as needed the parts remaining were cleaned up, with the brake lever itself polished...
... the return stop and master cylinder plunger added, these will be adjusted on commissioning, and the bush lightly greased before these were offered up and bolted into place on the bike...
... and the operation checked and the return spring fitted.
It looked like the return stop was going to impact the footrest stop as part of it's operation, so a self-adhesive rubber stop was added at the point of impact...
... to protect the footrest stop and avoid the annoying impact noise.
With pretty much everything done and all the parts arrived, it was time to double check and get the assembly finalised.
The new stainless banjo bolts and bleed nipples were put in with appropriate copper washers...
... to replace the old weather beaten fixing and torqued up.
As with all the other systems with fluid in, this will be added during the commissioning and therefore bled through at that time.
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