centering the calipers

[XJkid]

My front brakes are dragging and I have determined it is because my disks are not centered in the calipers. The manual says to rotate the fork while the pinch bolt is loose until the disk centers, but I cannot get the fork to move much. I checked the diagram and all parts are in correctly. Both calipers need to move outboard to center. Any ideas?

[MaximPhil]

XJKid,
Is there a Fork brace fitted? If so it needs to be loosened and follow the manual step by step. Assuming you put all the pieces back in the correct place
Phil

[XJkid]

no brace

No brace. I understand XJ's don't need them 'cuz of beefier fenders, which I had unbolted to allow for more fork movement.

[DiverRay]

Per the factory manual:
1. Tighten axle nut and install cotter pin. (76ft-lb)
2. Install front fender.
3. Before tightening pinch bolt, compress the forks several times to make sure of proper fork operation.
4. With the axle pinch bolt loose, work the right fork leg back and forth until the proper clearance between the disc and caliper bracket on the front fork are obtained.
6. Tighten axle pinch bolt. (14.5ft-lb)
So you need to work each fork tube so both discs are properly lined up. This is all per the Yamaha shop manual. Also, on the specials you need to be SURE the bolt that holds the caliper on is NOT BENT AT ALL. If it is, you will need to find a replacement.

[BA80]

Don't know for sure about the XJs but the specials have a machining flaw with the right front fork lower. They have to be centered manually. Basically by eye.

I've had to correct techs at the dealer on that issue when I was forced by circumstance to have tires replaced there.

[XJkid]

4. With the axle pinch bolt loose, work the right fork leg back and forth until the proper clearance between the disc and caliper bracket on the front fork are obtained.
.

This is my issue, Ray. I have a factory manual that I was following. The forks will not budge. I went so far as to remove the brake pads, mount the caliper, and drive a wood shim between the disk and caliper. Maybe got 1/64" movement. This is all done with a loose pinch bolt. The 1/64" I did get stopped the disk from scraping on the caliper, but it is still not centered.

[DiverRay]

If they are too close or far, it's probably the fender. Loosen the fender bolts a bit and try again. If it's really off, you may need to try and "gently" force the fender into position, in or out about 5mm.

[Jerry]

The XJ will benefit from a fork brace, just not as much as other 11s. I have one of Tkat's on my XJ. Note that the XJ version is different from the other 11 models; the parts that clamp to the fork tubes are taller so the brace can clear the fender. Braces from Standards and Specials will not work. If you do go the brace route make sure the brace is specific for the XJ.

The XJ's steering head (frame) has more reinforcement than the Standard or Specials as well. This was done to reduce flex and make the handling feel more solid. It is not all in the fender doubling as a fork brace. Differences are best seen with tanks removed.

As for centering the rotors, check you brake pads. In my experience they do not wear evenly; one side always seems to wear quicker than the other. This can make the rotors appears to be off-center. The manual procedure assumes new or near-new brake pads.

[XJkid]

As for centering the rotors, check you brake pads. In my experience they do not wear evenly; one side always seems to wear quicker than the other. This can make the rotors appears to be off-center. The manual procedure assumes new or near-new brake pads.

I removed the pads to take them out of the equation and remounted the calipers. Still off-center.

[bikerphil]

You can try shimming the caliper brackets which attach to the fork if you want them exactly centered. On the XJ, one fork, IIRC the right side, can be moved on the axle to center the caliper, the other side you could try shimming at the bracket with some thin washers possibly.