Front caliper problem - XT660Z 2011 - .: XT660.com

kinioo · # 1 18-09-16, 18:32

Afternoon all,

Has anybody experienced similar problem with front brake caliper (see pictures).

Its XT660Z 2011 non ABS

For reference I will refer to Right hand side (clutch lever) & left hand side (brake lever) as standing in front of the bike.

The problem:

as you can see the RHS (clutch side) caliper is rubbing/touching the brake disc.

And no, its not due to the worn brake pads as there is plenty of life in them.

There is absolutely no room to move caliper to the right due to the mounting bolts!!

Any ideas guys ??

Its rubbing so much that I can barely move the bike (I am not talking about riding it!!!)

I also attached two pictures showing front wheel spacers FYI (but I dont think they are installed other way round as it all had been fine for 5 years ?!)

P.S.

I had this problem a while back (3-4 years) and i took it to the local garage and the mechanic told mi to undo two security bolts on front wheel axle, then pump the front suspension few times etc. and it solved the problem - but not this time !!!

Chris

LHS spacer (clutch side)

LHS spacer (brake side)

kinioo · # 2 18-09-16, 19:39

Quote:

Originally Posted by Pepsi

I centralise everything by backing off the two pinch bolts on the right fork leg and also backing off ( quite a bit ) the axle bolt. Then pump and apply the front brake. Keep the brake on with a zip/cable tie and tighten everything back up. In my case I don't have the standard front fender and if you do you might need to consider undoing it so the lower legs can easily twist back to facing forward correctly.

Thanks, I will give it a go !

C.

kinioo · # 3 19-09-16, 20:53

Quote:

Originally Posted by Pepsi

I centralise everything by backing off the two pinch bolts on the right fork leg and also backing off ( quite a bit ) the axle bolt. Then pump and apply the front brake. Keep the brake on with a zip/cable tie and tighten everything back up. In my case I don't have the standard front fender and if you do you might need to consider undoing it so the lower legs can easily twist back to facing forward correctly.

Done this it didn't work.

Also removed both calipers, removed front wheel, re-assembled, still nothing!!!

Very frustrating! !!!

Any more ideas?

I can't even take it to the garage as I cannot ride it!!

Pleiades · # 4 19-09-16, 21:32

Slackening off the pinch bolts and bouncing the front will align the forks (ensure they are parallel) and help with RHS (brake lever side) caliper alignment with the disc, but it won’t have any effect on the LHS (clutch lever side) caliper at all. The horizontal position of the LHS caliper is fixed in relation to the disc by the axle spacer. Not only is it always in the same horizontal position, it will also always perpendicular to the axle. Only the RHS fork leg can slide in or outwards as its position is not governed by a spacer only by what point the pinch bolts are nipped up.

Looking at your clutch side caliper, the thing that grabs my attention is that the caliper body is not parallel to the brake disc, which it always should be; it is rubbing only on its upper/outer edge. As this caliper is in a fixed position determined by the spacer (and that it is rigidly bolted to the fork leg), it should be perfectly perpendicular to the axle and therefore parallel to the disc. Yours is not.

The only plausible ways for the disc and caliper to be out of parallel (like yours) are:

(a) The axle is not screwed tight into the LH fork leg (and therefore the spacer is not nipped up between bearing inner race and fork leg).
(b) You have excessive play in one or both wheel bearings
(c) The axle is bent or worn
(d) You have a warped brake disc
(e) The bobbins/springs have seized or broken and the disc is only partially floating and/or not centralised on its carrier.
(f) The caliper is bent or distorted

kinioo · # 5 19-09-16, 22:57

Quote:

Originally Posted by Pleiades

Slackening off the pinch bolts and bouncing the front will align the forks (ensure they are parallel) and help with RHS (brake lever side) caliper alignment with the disc, but it won’t have any effect on the LHS (clutch lever side) caliper at all. The horizontal position of the LHS caliper is fixed in relation to the disc by the axle spacer. Not only is it always in the same horizontal position, it will also always perpendicular to the axle. Only the RHS fork leg can slide in or outwards as its position is not governed by a spacer only by what point the pinch bolts are nipped up.

Looking at your clutch side caliper, the thing that grabs my attention is that the caliper body is not parallel to the brake disc, which it always should be; it is rubbing only on its upper/outer edge. As this caliper is in a fixed position determined by the spacer (and that it is rigidly bolted to the fork leg), it should be perfectly perpendicular to the axle and therefore parallel to the disc. Yours is not.

The only plausible ways for the disc and caliper to be out of parallel (like yours) are:

(a) The axle is not screwed tight into the LH fork leg (and therefore the spacer is not nipped up between bearing inner race and fork leg).
(b) You have excessive play in one or both wheel bearings
(c) The axle is bent or worn
(d) You have a warped brake disc
(e) The bobbins/springs have seized or broken and the disc is only partially floating and/or not centralised on its carrier.
(f) The caliper is bent or distorted

Thanks Pleiades,

Yes, you are correct - the disc is rubbing on the top of the caliper only!

Should I mention that it happened (I discovered it) when I wanted to use my bike after it had sat in the garage for a while???

Well it looks like I will need to go step by step (i.e. follow your a to f suggestions) and hopefully will find some solution?!

I would exclude a) as both spacers seat correctly (well it seams to me);

Re: e) what bobbins/springs ?? where do I find them ??

Thx

Pleiades · # 6 19-09-16, 23:18

Quote:

Originally Posted by kinioo

Re: e) what bobbins/springs ?? where do I find them ??

Have a look at this You Tube video and all will become clear!

Pleiades · # 7 20-09-16, 08:26

I see you edited your post and added...

Quote:

Originally Posted by kinioo

Should I mention that it happened (I discovered it) when I wanted to use my bike after it had sat in the garage for a while???

...which is a massive clue to what's probably gone wrong - seized bobbins!

Go straight to option (f) from my list after watching the You Tube video above.

kinioo · # 8 20-09-16, 09:22

Quote:

Originally Posted by Pleiades

I see you edited your post and added...

...which is a massive clue to what's probably gone wrong - seized bobbins!

Go straight to option (f) from my list after watching the You Tube video above.

Sorry, I should have mentioned it earlier - idiot!

Pleiades - thanks very much. Will watch video and will get my hands dirty.

Will let you know.

Thanks,

Chris

Pleiades · # 9 21-09-16, 00:16

Sorry, just noticed I said (f) when I should have said (e)!

Should read - "Go straight to option (e) after watching the You Tube video." But I'm sure you've got the idea that you need to free off the bobbins anyway!

kinioo · # 10 21-09-16, 20:25

OK, ****** - it looks like new front discs time !!!

Yes, bobbins are seized.

Cleaned them, they move just - no chance to turn them by fingers!!

However, clutch side disc is fuc**d anyway.

Long story short - new discs!!

1) Now what is the best source to get them from ??

2) I will also need two sets of disc bolts.

3) What is the best way to undo disc bolts - bearing in mind bobbins were seized, so I cant even think how bad will be removing the bolts !!!!

Many thanks,

Chris

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