Brake Job Emergency Help Please - Kawasaki KLR 650 Forum
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post #1 of 18 Old 07-06-2011, 10:08 PM Thread Starter
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Brake Job Emergency Help Please

Ok. I've done a gob of brakes before, but have never had this happen.
They're binding, for lack of a better term. They have a pretty damned good grip of the rotor.
I had the pistons as far back as they would go before I re mounted the hanger. They slid right onto the rotor very easily.
Any two cents please. It's my only vehicle.

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post #2 of 18 Old 07-06-2011, 10:19 PM Thread Starter
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Follow up.
Took the caliper back off. I can push the pistons back in and it will slide back onto the rotor easily like it should.
But it's binding enough that on my test drive, it blued the rotor.

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post #3 of 18 Old 07-06-2011, 10:49 PM
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Fluid good?




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post #4 of 18 Old 07-06-2011, 10:54 PM Thread Starter
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Ya. I'm starting to think that the inner pad (piston side) is binding up on the hanger. I'm going to fiddle with them some more tonight and maybe even toss on the old pads for a run around the block to make sure that it doesn't bind up with the old pads.
If that's the case and I have no more amazing ideas, I'll take these pads back to cycle gear and head to the dealer to pick up the OEMs and see if they've seen that before.
But if yall have ANY ideas, post away please.

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post #5 of 18 Old 07-06-2011, 11:37 PM
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Yes, some after market pads have been known to need a trimmin' to fit. If you don't have access to a bench grinder AND know where and how much to buzz off, you might want to go get those OEM pads. If you grind too much off the tabs, the pads could work out of the hanger and get wedged between the hanger and the rotor.

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post #6 of 18 Old 07-07-2011, 12:00 AM Thread Starter
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I'm always one for making sparks fly. Grind away I did. It does seem to fit better now. You know...snugly, but without having to pummel it with steam engines to fit kinda of snug.
It still rubs though, and I know pads always rub a bit. So this I must ask. How much rubbing is too much rubbing? (I've already accepted there will be jokes...as a matter of fact, I'd be sad if none turned up)

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post #7 of 18 Old 07-07-2011, 12:08 AM
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Trab -

The calipers slide on a pair of studs - they go in and out of the rubber boots. These need to be lubed occasionally with a silicone-base grease. If you cannot slide the studs in and out of the socket with finger pressure, then they will bind.

Take them apart, shoot some silicone grease in there (regular grease will eat the rubber, silicone grease is just dielectric stuff) and they should be good.

This is Gen2 stuff.

T

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post #8 of 18 Old 07-07-2011, 12:16 AM Thread Starter
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Just got back from a 1 mile test ride around our 'hood. Max speed about 40. I'd say average 25-30. Didn't use the front brake. Just down shifting and rear brake. When I got back, the rotor was hot, but not hot enough to burn my hand. Still binding too much right?

Tom,
I looked at those and did move them in and out, though I don't recall off hand how much pressure I needed to do so.
What's the general procedure to take those two pins down? (you're referring to the hanger to caliper pins, correct?)

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post #9 of 18 Old 07-07-2011, 12:19 AM
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Quote:
Originally Posted by TrabFTW View Post
I'm always one for making sparks fly. Grind away I did. It does seem to fit better now. You know...snugly, but without having to pummel it with steam engines to fit kinda of snug.
It still rubs though, and I know pads always rub a bit. So this I must ask. How much rubbing is too much rubbing? (I've already accepted there will be jokes...as a matter of fact, I'd be sad if none turned up)


I've had pads that didn't slide smoothly in the slots, rough edges on the ears. Filled them down and also used a bit of hi-temp grease so they move freely.

Did you clean all the old brake dust off with brake cleaner?

Might have too much brake fluid if you topped it off when the pads were worn. I replace the fluid when I change pads.

One more thing did you tighten the axle before you noticed the pads dragging?

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post #10 of 18 Old 07-07-2011, 12:20 AM
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No, not the pins that are removable from the caliper. Let me see if I can find a picture.

T

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The kid poured him another straight rye and I think he doctored it with water down behind the bar because when he came up with it he looked as guilty as if he'd kicked his grandmother. -Philip Marlowe

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

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