Brakes calipers won't line up

[lakecountrydave]

I (plus my brother & his buddy) cannot get the left brake caliper to line up so that I can bolt it to the fork. I took the bike down to the frame and painted it. I am almost done putting her back together, but cannot seem to get the front brakes installed. I had the wheel on with the disk perfectly centered in the slots on the fork. I was having this same issue, so I bought the rebuild kits from Georgefix and rebuilt the calipers. I even used a c-clamp to make sure that the piston is fully in. I loosened the fender, and I do not have the castle or pinch bolts tightened per the book. I am using new pads from Parts & More. I have tried moving the right fork leg, but it still does not line up. Does anyone had an idea why the caliper will not lineup with it's hole? Or better yet how I can make it. Having gotten past my coil mounting issues I can almost taste the bugs in my teeth and now this!

[DGXSER]

This being a Special model, you have one bolt each side that goes straight up through the center of the caliper and has the angled brake pads, correct?

Are you certain the tips on the brake pads is lining up with the corresponding slots in the fork? Did you keep the pads separate, as in there is a left set and a right set. Otherwise, I am not sure why it would not line up.

[lakecountrydave]

Yes, 1 bolt through each caliper, and I kept the pads in their original packaging until I put them on the calipers 1 at a time. They are the crazy angled pads. I have now loosened all of the fasteners on the trees. I cannot find my wrench so off to Sears to get a new one before everything closes. Then back at it.

[DGXSER]

Dave, maybe a picture of the setup before mounting it and perhaps as close as you can get it to lining up? Does it not want to push up to mate with the flange? Or is the bolt hole no where near the bolt?

[bikerphil]

Those Special pads are easy to get mixed up, just had to figure this out the other day:

The thin edge of the pad should be facing forward on the outboard side of each caliper. The thick edge faces forward on both inboard pads.

Don't know if this is your problem Dave, but worth a shot checking. Like DG said, make sure those tangs on the pads are up in their slots in the fork, they can slip out sooo easily, you really have to look up in there to make sure they're good. What helps too is, after slipping the caliper on the rotor, lightly pull the brake lever and tighten the piston to the rotor. This'll hold the pads more stable and they won't fall out of those F'n slots.

[lakecountrydave]

Thanks guys I guess that I am just not that bright. Despite the fact that I went to the parts and more site and labels the boxes, and then came to this site to verify that I had the right part numbers for each side I still attempted to put the pads on the wrong sides. Once I figured out my mistake they went on like butter I appreciate all the help, and I am guessing that I will finally be able to go for a ride tomorrow! All that is left is bleeding the brakes, making the plug wires, oil, tank and seat.

[bikerphil]

Lol, yep those calipers can be a pain, glad you got it together.