Little help please from Mk1 owners

[Bikespod]

Hi all.
I’m after a yuck bit of help from any Mk1 owners.
I recently noticed a deformation in the carrier on one of my front discs. Presumably from a presenter doing the ride off with disc lock trick.
So I have replaced the discs with EBC discs.
They seem to be identical on installation and work very well in use ( an improvement in fact )

Some Facebook users in a VFR group said that they had to install spacers behind the ABS ring to get the ABS light to turn off once on the move due to an excessive air gap between the ring and sensor.

Now, my light goes off as expected and no error, BUT the gap is more like 2mm.
The manual states “0.8-0.9mm gap. No adjustment possible, if not in range, check installation and parts for deformation”

So my request is for someone to please look down the line of the ABS ring and visually check the gap between it and the ABS senor on the bottom of the calliper carrier bracket.
Better still to check it with feeler gauges to measure it.
I’m wondering if my calliper bracket suffered in the incident and is slightly bent.

Any help much appreciated. Thank you.

[reasty]

Hi - l can't lay my hands on my feeler gauge at the moment but can safely say the gap is below 1mm as  I've tried a 1mm plastic packing shim and it won't fit the gap - if I find the feelers tomorrow I'll try for an accurate measurement.

[sneo]

No more than about 0.5mm using a piece of card and a caliper to measure

[Bikespod]

Thank you both. That really helps. I’m more convinced that the calliper carrier bracket is a bit bent.
I have some used callipers with brackets coming soon. I’ll swap out the bracket and see if that works. If not I’ll have to pack the ABS ring out to get the correct gap.
Thanks again.

[reasty]

Let us know the outcome - sounds like a bit of conundrum-hope it works

[Bikespod]

So. I received the used callipers with their carriers. Swapped the carrier and installed on my calliper and fitted the sensor.

Same gap 1.8mm

Got back in touch with EBC and they have been absolutely brilliant to deal with.
They listened to my questions and acted on my request to measure the original disc carrier thickness and compare it to their Honda disc in their library.

Guess what…..the EBC carrier is 1mm thinner than the Honda one.

They have given me the option to wait a few months and they will manufacture new discs and thicker carriers to replace the ones I have, or I can shim the ABS ring on the ones I have by 1mm.

I think I’ll go for the new discs rather than shimming the ring.

What a refreshing company to deal with. They have admitted their mistake and are going to correct it for future discs. And supply replacement discs free of charge. I do have to return these discs, but that’s only fair.

Just hope I can get the loctite to release easily.

[Corringdon]

Good result, Bikespod.

[Bikespod]

Yes. A good result. And I’ve ended up with a spare set of callipers I can strip and refurb with new seals etc. Nice little project for the winter months.
Might even put stainless pistons in too 😉

[Semyooon]

Originally Posted by Bikespod

Yes. A good result. And I’ve ended up with a spare set of callipers I can strip and refurb with new seals etc. Nice little project for the winter months.
Might even put stainless pistons in too 😉

Nice.

I also have everything set to start reassembling the calipers - new seals, etc.
And I am planning to replace the rotors with brembo set - so will let everyone know if there are any troubles.

[Bikespod]

Sorry about previous posts. Gibberish thanks to auto correct.

Just so others are aware. I don’t think EBC are making the carriers thicker after all. Presume they will add some shims to future shipments.
 
They sent me a brand new set of discs and pads, and let me keep the originals.

I used stainless washers to shim the ABS ring and now have a perfect air gap on the new discs.
So end result is brand new brakes and a spare set of discs in the cupboard.

Heads up for others who might not know. Don’t use the supplied ABS ring bolts from EBC. Use the Honda ones. The supplied ones rust and are made of soft steel. Also use the medium strength loctite, not strong stuff. I had to drill out the EBC bolts and struggled getting the disc mounting bolts out of the wheel.