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Old 06-15-2013, 07:06 PM   #8146
bmwktmbill
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Joined: Jul 2005
Location: Traveler
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Quote:
Originally Posted by mcguyver View Post
The inner face (alloy) on my rear brake caliper has worn due to the pad vibrating against it over time. (Possible due to worn brake pad retaining pin as well)
This causes the pads to wear on an angle and wear out prematurely.

Bike has done 60000klms.

Any one know of a reasonably priced aftermarket caliper?

Ignore the dirt, but tis pic shows whati mean.

File the face flat?, new pin?

Disc bent?

bill
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Old 06-16-2013, 01:53 AM   #8147
ericGSsti
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Location: Dublin, Ireland
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Quote:
Originally Posted by mcguyver View Post
The inner face (alloy) on my rear brake caliper has worn due to the pad vibrating against it over time. (Possible due to worn brake pad retaining pin as well)
This causes the pads to wear on an angle and wear out prematurely.

Bike has done 60000klms.

Any one know of a reasonably priced aftermarket caliper?

Ignore the dirt, but tis pic shows whati mean.


The retaining pin seems to be causing the uneven wear. My bikes parked at my job at the minute so I cann't check against my bike but it just looks out of place. Could be wrong.
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Old 06-16-2013, 04:38 AM   #8148
Alik
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Quote:
Originally Posted by mcguyver View Post
The inner face (alloy) on my rear brake caliper has worn due to the pad vibrating against it over time. (Possible due to worn brake pad retaining pin as well)
This causes the pads to wear on an angle and wear out prematurely.

Bike has done 60000klms.

Any one know of a reasonably priced aftermarket caliper?

Ignore the dirt, but tis pic shows whati mean.

In that case I would weld the missing material and grind it or machine it flat.
In my case the hole for the pin statred to wear - have to do something about it.
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Old 06-16-2013, 09:22 AM   #8149
Beta450
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Try flipping the pin over so the brake pads are not in the wear grooves and see if that helps. It will give you time to order a new pin.
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Old 06-16-2013, 11:23 AM   #8150
bigboyxl
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Location: Czech republic - Ukraine
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Quote:
Originally Posted by clintnz View Post
I've fitted Symtech grip heaters to 3 different bikes now & we really like them. I find the 2 heat levels to work well for me. Insulate under the clutch side one with adhesive lined heatshrink. Only issue over many miles of use has been the plastic rocker switch that came with the 1st set which crapped out - get the metal toggle switch.

Check the wiring to the clutch lever sensor too - this is more likely to be the issue than the sensor itself in my experience.

Cheers
Clint
oh thanks for tips on symtec heater!
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Old 06-16-2013, 01:29 PM   #8151
clintnz
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Location: Rotoiti, New Zealand
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Quote:
Originally Posted by mcguyver View Post
The inner face (alloy) on my rear brake caliper has worn due to the pad vibrating against it over time.
I have the same thing. I filed down the caliper to get the faces paralell again. The voices in my head told me I was a naughty engineer & I wouldn't recommend anyone doing the same I sure as hell wouldn't do anything like that on my front brakes. But it has worked ok.

I've replaced the pin several times too, & put a steel bush in the caliper where the LH end of the pin had worn it's hole out a while back

There is also other wear on my caliper now at 120K km so I'm about to order a new one, would be interested in any aftermarket alternatives too.

Cheers
Clint
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Old 06-16-2013, 02:40 PM   #8152
singletrak
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[QUOTE=dirty_sanchez;21632599]An easy fix. The exhaust stud on the left side of the head is threaded all the way into the wet part. Pull that stud and apply some 5770 Loctite thread sealant on the threads and reinsert. Presto chango-the fix is done.

My leak is on the throttle side. Is left facing the bike or on the bike?
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Old 06-16-2013, 07:39 PM   #8153
Gerst
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Quote:
Originally Posted by mcguyver View Post
The inner face (alloy) on my rear brake caliper has worn due to the pad vibrating against it over time. (Possible due to worn brake pad retaining pin as well)
This causes the pads to wear on an angle and wear out prematurely.

Bike has done 60000klms.

Any one know of a reasonably priced aftermarket caliper?

Ignore the dirt, but tis pic shows whati mean.


I had a similar issue recently. Luckily all I needed was a new pin and brake pads. With the wheel off it's pretty simple to move the brake pads on the pin to check for wear. I waited 25,000 miles and was lucky the pin didn't fail and cause all kinds of havoc.

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Old 06-16-2013, 07:47 PM   #8154
mcguyver
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So does anyone know of an aftermarket caliper?

Not really keen on filing the oe caliper flat.
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Old 06-16-2013, 07:55 PM   #8155
bmwktmbill
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Quote:
Originally Posted by mcguyver View Post
So does anyone know of an aftermarket caliper?

Not really keen on filing the oe caliper flat.
Will this help?

http://www.cyclebrakes.com/html/brembo_calipers.html
bill
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'02 KTM 640 Adventure-lowered
"On the road there are no special cases."
Cormack McCarthy-The Crossing

The faster it goes the faster it breaks.
And high performance=high maintenance.
Bill Shockley
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Old 06-16-2013, 08:08 PM   #8156
mcguyver
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Thanks Bill
Application chart only shows to 2002. Not sure if the later models had the same caliper.

Have sent them an email.

Thanks again.
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Old 06-16-2013, 08:28 PM   #8157
clintnz
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Location: Rotoiti, New Zealand
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Quote:
Originally Posted by mcguyver View Post
Thanks Bill
Application chart only shows to 2002. Not sure if the later models had the same caliper.

Have sent them an email.

Thanks again.
Looks like the same KTM part number 97-04 then a change in 05 although they don't look any different. be interested to know the price if you find a source.

Cheers
Clint
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The wilderness, the desert - why are they not crowded
.................................................. .....with pilgrims?
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Old 06-28-2013, 05:21 AM   #8158
singletrak
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Anyone remove or modify their chain guards? I installed a new Michelin Dessert tire (140), it is rubbing on the chain guard I removed the chain guard and everything is fine. Is there a mod for the chain guard where you remove the lower half of the chain guard (the part that wraps around the swingarm)? It looks like there are two rivets that hold the upper and lower section together.

Singletrak
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Old 06-28-2013, 07:10 AM   #8159
wrk2surf
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took my guard off in 2005 and havent looked back..
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Old 06-28-2013, 10:51 AM   #8160
skibum69
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took my guard off in 2005 and havent looked back..
Yeah you desert guys have all the luck
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