Need help...brakes on an 06!!! - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 16 Old 06-09-2015, 08:58 AM Thread Starter
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Need help...brakes on an 06!!!

Sooo....pulled the rear tyre and replaced the tube. Put the wheel back on, reattached the brake....and there is considerable drag against the disc. The brake lever wasn't touched, I didn't frig with the caliper....I looked at it and can't figure out if there is a way to adjust the caliper seating left or right......any ideas ladies and gentlemen???

By the way....new to Kawasaki's....not an excuse, just means responses may need to "dumbed down" a tad.

Thanks
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post #2 of 16 Old 06-09-2015, 10:29 AM
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Well, the "new to Kawasaki" tells me that you've ridden and had other bikes.

Welcome!

I would loosen the rear axle nut and make sure that something didn't get caught in the caliper mount slide area. Or, check the caliper mounting where it slides on the pins and make sure that it's not at any angle.

With any repair that goes sideways, (I've had plenty) take it apart to where you think the issue might be and very carefully go step by step making sure each component is working before you go on to the next step.

NOTE--- On any repair, clean as you go. make sure things are cleaned, then lubed if needed. Get that old crap out of there.

Hope it helps, and good luck.

Confidence is the feeling you have before you fully understand the situation."

Jeff in Napa California
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post #3 of 16 Old 06-09-2015, 10:30 AM
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A number of possibilities . . . axle misalignment, absence of right-hand spacer on reassembly, sticking caliper piston . . .

My first step when removing rear wheel . . . unbolt caliper, push piston in as far as possible to facilitate reassembly . . .

Sandwich disk into caliper, after everything lined up.

In your case, since you did nothing to the pads and didn't touch the brake pedal, mis-assembly seems likely, to me. Been there, done that . . . rear brake assembly is really cryptic to me, somehow. Suggest you disassemble/reassemble, with careful attention to alignment of axle, being sure the rear axle spacers are all present and in the right order (easy to get 'em mixed up).
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post #4 of 16 Old 06-09-2015, 11:21 AM
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Remove the rear caliper and check to see that the caliper assembly slides in and out on the two pins with little effort. If not, remove, clean, and reassemble with silicon grease.

If the pins are allowing free movement, then pry the pads apart to provide plenty of clearance to the brake disk and reassemble. Operate the brake lever several times and see if there is improvement.

Tom

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post #5 of 16 Old 06-09-2015, 12:40 PM
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Been there, Done That.
I usually remove '07 and older rear wheel with the brake caliper still on the bracket. But every now and then, I dislodge the outer brake pad from it's proper location upon reassembly.
With the wheel still on the bike, Remove the 2 mounting bolts and reassemble the pads and caliper onto the bracket correctly.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #6 of 16 Old 06-09-2015, 12:56 PM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
Been there, Done That.
I usually remove '07 and older rear wheel with the brake caliper still on the bracket. But every now and then, I dislodge the outer brake pad from it's proper location upon reassembly.
With the wheel still on the bike, Remove the 2 mounting bolts and reassemble the pads and caliper onto the bracket correctly.
Thanks to all for your input....this sounds like the most likely scenario. I removed the wheel with the caliper on the bracket, but when I went to put it on I messed with it for 10 minutes and couldn't get everything lined up correctly so I removed the caliper.

Confusing part is I am a little unsure about what "correctly" looks like...

Thanks again for the assistance
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post #7 of 16 Old 06-09-2015, 06:16 PM
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Quote:
Originally Posted by Operator View Post
Thanks to all for your input....this sounds like the most likely scenario. I removed the wheel with the caliper on the bracket, but when I went to put it on I messed with it for 10 minutes and couldn't get everything lined up correctly so I removed the caliper.

Confusing part is I am a little unsure about what "correctly" looks like...

Thanks again for the assistance
Another one back on the road!!!!
And all done with hand tools.

(bimmer special tool jab there)

Confidence is the feeling you have before you fully understand the situation."

Jeff in Napa California
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post #8 of 16 Old 06-09-2015, 09:25 PM
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Geez, just 'cuz I need a $30 filter wrench to get the oil filter off because no standard off-the-shelf wrench fits you'd think special tools were the order of the day for them Bimmers. Well, that and the special tool for removing the spark plug caps. That's about it, though.

Oh, wait. There's that tool for the alternator belt. That's really about it, though. Except for the whole thing is put together with Torx fasteners.

Everything else can be done with normal hand tools. Except the front axle; that takes a special wrench, but it's not all that special.

Um, replacing the headlight bulbs takes special tool, but it's shop-made and really ot an official tool, so that doesn't count even though you can't really easily do it on the road.

Oh, yeah, the oil filler cap takes a special tool, but they give you that, so that's not a big deal. Just don't lose it.

What's so bad about all that? All you really need to fix the thing if it goes tits up on the road is a credit card.

Tom
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“On the way downtown I stopped at a bar and had a couple of double Scotches. They didn't do me any good. All they did was make me think of Silver-Wig, and I never saw her again.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
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post #9 of 16 Old 06-09-2015, 11:09 PM
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Sorry Tom.
I truly didn't know your day was worse than mine.
Most of mine are, BAD. For one reason or another!

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #10 of 16 Old 06-10-2015, 08:16 AM
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Quote:
Originally Posted by Tom Schmitz View Post
What's so bad about all that? All you really need to fix the thing if it goes tits up on the road is a credit card.

Tom
Yes, credit cards are the universal tools. They can provide special and common tools plus the guy that knows how to use them!

A credit card has helped me fix more stuff than I care to admit.
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