Rotor problem: Why is this happening?

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Scribe, Apr 30, 2012.

  1. Scribe

    Scribe £Bob£

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    Front right rotor on my 950 Adventure. It looks like it is so close to the caliper bracket that it is actually scraping the rotor. Why would that be?
    * I tried loosening the axle clamps and pumping the fork to align the legs. No difference
    * Brake pads don't look wonky or unevenly worn
    * caliper seems to slide just like it should
    * Could I have bent the caliper bracket somehow? I have dropped the bike recently, though I don't see any obvious damage.
    I'm stumped. What you got?

    [​IMG]
    #1
  2. DirtyADV

    DirtyADV Long timer

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    Have similar issues on my -04, its the right side caliper scraping right? I simply push the front axle so its like 1 mm in the right side clamp rather then flush with it.

    /Johan
    #2
  3. slackmeyer

    slackmeyer Don't mean sheeit. .

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    Check that your axle is pulling in all the way. I've seen this problem before when there was a ding on the end of the axle, and it wasn't seating in the right side fork leg far enough.
    #3
  4. Zuber

    Zuber Zoob

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    Your forks are still out of alignment. I'll bet the right fork clamp is hanging up on the axle.

    Loosen the clamp, pry back the brake pads, kick the fork leg over, pump the forks without using the front brake, tighten the clamp, then check it.

    If that doesn't get it back in line, you'll need to pull the front wheel and check whether the fork axle clamps are not lined up. Put just the axle in the left clamp first, then slide it back over to the right hand clamp (left/right is as you are sitting on the bike). It should slide right over with no hangups. You may need to slide one of the fork legs up or down in the triple clamps to get them exactly in line. Remove and nicks on the clamps that hang up the axle. Use a tiny amount of grease and try the assembly again.
    #4
  5. Konflict Motorsports

    Konflict Motorsports KM TUNER

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    I agree the forks are out of alignment, make sure your axle is lubed with a waterproof type grease and it should not be such an issue.
    #5
  6. uk_mouse

    uk_mouse Aquatic adventurer

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    Yup, I'm with Zuber on this - the key part of his post is "pump the forks without using the front brake". If the brake pads are touching the discs, it'll stop the forks moving into their correct place on the spindle.

    Furthermore, I try and nip up the spindle clamp while holding the forks in a slightly compressed position. If you let them extend fully everything can pop out of alignment again.
    #6
  7. Sumi

    Sumi Long timer

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    Also make sure that you are using 950ADV spacers and they're installed on the correct sides..

    I would think that it'd be nearly impossible to bend the caliper bracket... And if you've droped the bike recently, it's most likely that the forks are out of alignment, as others have said already.

    Here is a good writeup on how to realign the forks (ofcourse you don't have to remove them, so just scroll down until the reinstallation part begins):

    http://ktm950.info/how/Suspension Shop/Forks/Remove and Replace/forkleg_rr.html
    #7
  8. zedtours

    zedtours Been here awhile

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    Take out axle spindle and bevel off RH end as it burrs after being knocked in a few times.
    #8
  9. Scribe

    Scribe £Bob£

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    Thanks for the replies. On my way out to the garage to try again.
    #9
  10. 1stiski

    1stiski Ride that nasty thing

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    my 04., FOLLOW THE mounting procedures from the service book. Be sure your spacers are on properly. Never had that issue.
    #10
  11. BoulderGuy

    BoulderGuy out ridin'....

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    As stated earlier, don't think your axle is in all the way. It should be 1 m or so inboard of the face of the aluminum, not flush which is where I would guess it is. Pull it and grease the crap out of the axle and try again. And yeah, follow the owners manual as to the correct way to install the front wheel......
    #11
  12. newbaumturk

    newbaumturk Adventurer

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    My issue was largely due to the fork bushings being worn out causing the fork to not line up when compressed.
    Also if the fork lengths are not the same it can cause issues
    #12
  13. Scribe

    Scribe £Bob£

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    Bingo! I deburred the axle and made sure it was in all the way and everything lines up all nice and pretty now. Thanks for the info
    #13