Help, what the heck have I done?

skydivr

Jumps from perfectly good Airplanes
Donating Member
I have totally screwed something up, and for the life of me can't figure out what I did.

I had noticed recently that my GENII was oscillating on braking, like it's catching/releasing, and after Twobrother's post about potential disc warpage, I got to wondering if I had the same problem. Last night I pulled off my front wheel and looked at the brakes, and noticed something amiss. In the three pics below, you will see the 1) Right caliper (fine); 2) Left caliper and 3) left caliper detail. Notice how the inside pad on one side is fully extended, and the other side compressed SO BAD that the pad is now flush with the nib on the caliper, and has actually started touching (last pic)....and this is the way it runs when the caliper is ON the bike (does not float back to center).

Tuf and I talked about this last night for awhile, and the only thing we can think of is the following:

- Spacers: maybe somehow I got the front/rear swapped out, or the front busa with the front gixxer...
- Axle: Maybe I got the busa swapped with the gixxer (wouldn't think so but ya never know). Gixxer's running fine BTW.
- Wheel: Have I got the wheel turned around backwards?

Confirmed with Justin that 08 busa and 07 gixxer 1k part numbers are same with spacers (front-front, back-back), but the axle numbers ARE different. I don't see how I could have swapped parts, but it's possible I guess.

Lastly, the last front Q2 I ran out had some really weird wear issues (high/low spots), I just put a new one on a few hundred miles ago, and it's already showing the weird wear pattern. If the wheel is ocsillating wrong, then that might also create that wear pattern.

Ideas? Of course, it WOULD be the week before the bash. I can't ride it like this. Maybe now I need an OEM disc on that one side, and in all likelyhood new pads (which I have, but if I don't fix the real problem I'll just be wasting another set). It's got to be something simple, since I didn't do that much. But who would have thought?

I need another GENII to look at, compare and measure the axle, wheel, disc and spacer...:please:

IMG_1254.jpg


IMG_1253.jpg


IMG_1257.jpg
 
Strange? The caliper itself is rubbing on disc?

It's obviously touched, although I think just barely started to as the pad wears down, otherwise it would probably already have tossed me.;...
 
It looks like it’s done more than just barely touch… If you look at the other side of that caliper (same spot as the wear marks) you can see where there was a little nipple on the caliper. That has been completely worn down and it is wearing into the body of the caliper. Hope you get it figured out before the bash.
 
Yikes ::9 I've never swapped out brake pads on the Busa, but are you missing spacers on that one side?

I do hope you figure something out before the Bash...just glad you spotted the problem before all the riding!
 
In my non-mechanic opinion, it looks like the pistons are stuck in the retracted position. This is why the other side is extended all the way to compensate for the opposing side not moving. Try to take the pads out and see if the pistons move in when you compress the brakes. Be sure to not compress them too much and put a wedge in the other caliper or put it back on the bike.

If the pistons are stuck, just get some WD-40 and lube the hell out of them to try and break them free. If not, the caliper will need to be rebuilt.

Also, I might be wrong, but weren't you the one that thought he lost a spacer on the front axle, but there is only one? I did the same thing about 3 years ago, that is why I remember answering the question about the spacer. Anyway, I think it is impossible to assemble the front axle incorrectly, but make sure the spacer is on the correct side. I think it is the right side of the bike as you are sitting on it.

Let us know.
 
have we rule out bearings? is there any play side to side on the axle?

I bet it turns like a demon to that side. :laugh:
 
I'm wondering why the sides of the pad backing plates are touching the calipers. Seems there should be some clearance there like in the top picture. You may also have air behind the pistons preventing them from being pushed out. Did you bleed the lines and calipers?
 
Tim and I had a good conversation. He thinks the piston may be stuck, as he's seen, and repaired some bikes with same problem before. My neighbor (a lurker on the .org) is going to bring his bike over tonight, and I'm going to measure all his parts and compare, and maybe even swap wheels to see how it lines up/compares. Also, Tim has graciously offered to bring a spare caliper with him to the Bash if I can't get it cleaned/unstuck.

No, no air in lines...and all the axle spacer appears to be correct. Now, if I could just get off work so I could go home and work on it - bothering the crap out of me trying to figure it out...
 
Tim and I had a good conversation. He thinks the piston may be stuck, as he's seen, and repaired some bikes with same problem before. My neighbor (a lurker on the .org) is going to bring his bike over tonight, and I'm going to measure all his parts and compare, and maybe even swap wheels to see how it lines up/compares. Also, Tim has graciously offered to bring a spare caliper with him to the Bash if I can't get it cleaned/unstuck.

No, no air in lines...and all the axle spacer appears to be correct. Now, if I could just get off work so I could go home and work on it - bothering the crap out of me trying to figure it out...

If it falls out with you neighbor, I can probably get some measurements on mine a little after 6 tonight.
 
Twobrothers said he'd take his off and measure it if I need him to thanks Detroit!
 
Back
Top