caliper bolt misalignment

[service writer]

Hi Folks,


I bought my first bike from my brother a few weeks back. It is the xj1100j. It has sat for 17 years and I have had my share of challenges. While I may hit more brick walls, but I have one I’m stumped on. A little background: The last time my brother rode it, he just put new tires on. After taking it, he said it had a handling problem, like the bike wanted to tip back and forth. For whatever logic, he got disgusted and just parked it. About 5years later, he got the bug again, started it drove it out of the garage and found he had brake problems. Disgusted again, he parked until I picked it up.

Seeing that the rear brake pads were worn down to nothing, I decided to change them. For worn pads, the caliper was still stiff to pry off. When I put the new pads on the bolt didn’t line up, I can force it on, but will completely lock up the rear wheel and looks out of whack from forcing it.
http://www.flickr.com/photos/10336364@N02/870035454/




I suspect that when the tires were changed that the alignment or positioning of the rear wheel was messed up. I tried to loosen the rear axle pinch bolt and axle nut to try shifting the position
http://www.flickr.com/photos/1033636...n/photostream/


I also checked and adjusted the swing arm.

What gives?

Thanks, Paul

[Ken Talbot]

Are you sure you have the correct pads, and have them mounted correctly? The rear unit for your XJ looks like the pivoting units on the front of Specials. These take tapered pads that at first glance look like they must be worn out because one edge is way narrower than the other. The beveled pad has something to do with the way the caliper pivots to operate, and I'm not positive that the pads for one specific location would work in another location???

[mitch]

Piston

Did you take a C-Clamp and shove the piston all the way back in? Careful cause it could cause your brake fluid to over flow out of your master cylinder. Make sure you have the cover off . But you knew all that
Doug

[service writer]

Ken, Doug,
Thanks for the replies.

I’m wondering about the pads too, but even the worn ones seemed to bind a bit. Although the caliper was pretty stiff from setting so long. I had to flush out the brake fluid as it looked like mud. Caliper is seating back far enough but still the bolt is ¼ inch or better away. The tires have about 5 miles on them, and still question if there could have been a reassembly problem.

The replacement pads are beveled…seem to be the same as the old ones…. Can they be put on any other way? I'll see if I can locate a app.guide to verify. I won't be a happy camper if they aren't. Although on the other I guess I would be considering the pickle I'm in

Is there any rear axle adjustment to move the caliper bracket/ swing arm closer to the wheel?

I adjusted the front swing arm adjustment as far as I could go without going over spec of 1/16th inch difference.

[service writer]

I found the application guide and confirm they are the correct pads.

[service writer]

I have new thoughts. If the swing arm or axle is out of alignment, the caliper bracket that is affixed to them would also be out, but would then rub on the rotor. Since the caliper bracket is just about centered on the rotor, I'm ruling out alignment. Caliper is fully compressed.

I need to get another set of pads from another manufacturer to compare, unless anyone else can verify this. The old pad is worn on the opposite angle from the new pad. For that matter the thickest point of the old pad is thicker than the thinnest point ( or corresponding point) of the new pad. Take a look:

http://www.flickr.com/photos/10336364@N02/?saved=1

[fredintoon]

You poor beggar - - -

- - - I only have those weird harold calipers on the front of my XS11SG but you gottem all round. OK, the wheel is socketed into the hub so the wheel itself and hence the brake disk is located where it has to be. The caliper centres itself onto the brake disk so it's in the right place too.
But the caliper swivel bolt don't line up.
This only leaves the caliper mounting bracket.
Is there a spacer that your brother put on the wrong side of something to leave that bracket in the wrong place?

[fredintoon]

OK we are leapfrogging our posts here.

The new pads look right for thickness but they are a left-side & right-side pair. Are you putting them in the correct sides of the caliper? Try swapping them?

[service writer]

Re: You poor beggar - - -

Originally posted by fredintoon
- - - Is there a spacer that your brother put on the wrong side of something to leave that bracket in the wrong place?

Hey Fred,

That was what I thought also, but the bracket is pretty well centred on the rotor. If anything it would want to shift in the opposite direction.

I don't see how the pads can be put on any other way.

[service writer]

Beggar yes, but I pay my dues on a auto repair forum..

There is a hole for the pin to go through, since it is only at one end, it is impossible to reverse....as I see it.

Is it possible that the bevel is in the incorrect position. That is did the manufacturer bevel the wrong sides? Mis box?

The part number is right.

I don't know if the bevel will wear to the opposite angle...like the old pad shows.

Thank God for beer.

[Ken Talbot]

Originally posted by service writer
The old pad is worn on the opposite angle from the new pad.

This may be the answer. If you look at the caliper's pivot bolt, you will see it is off-centre from the rotor. That is why the pads are bevelled, to move the friction surface of the pad set parallel to the rotor. Have a look at yours and see if that is happening. I'm guessing you've inadvertently ended up with a 'left hand' set of pads instead of a 'right hand' set, or vice-versa. If you spilled the old pads back on, would that that change the alignment and allow the pivot bolt to back where it belongs?

[service writer]

Hey Ken,

I think we are on the same page . An hour ago I threw on the old pad for the inside position and it was fine. I was thinking the manufacturer flipped the linings in production, but you are more on the mark regarding the left and right side sets. This has to be the answer....or it is the only logical one that makes sense anyways!!!

I'll touch base with the dealer and see what I can learn

[Ken Talbot]

Take your old ones in when you go to see the dealer, and take in the new ones that don't fit. Ask for another set just like the new ones you already have "only different" . That should get you on the right track!

[trbig]

Looking at those pics... the pads are not installed all the way. They are hanging down and need to rotate forward to the front. There is a tab on the pads that fits into a slot on the front of the caliper as you slide the whole thing forward. Maybe you had this done already.. but...





And the pad that has the thickest part of the bevel on top needs to be on the outside of the disc. (Right side looking at it from the rear.




And Ken is right.. these are the same part number for the specials' front pads. They only go ont the back though. The front pads are a different number.
Tod

[service writer]

Thanks for the pic tod, that seals it.

By chance do you know the correct part number.