Front Calipers sticking / died - Fixed I'm an Idiot

Discussion in 'Hard. Core. (1090/1190/1290)' started by tr0yy, Jun 22, 2019.

  1. tr0yy

    tr0yy Been here awhile

    Joined:
    Jan 13, 2013
    Oddometer:
    195
    Location:
    in the wind
    Bike : 2015 1190 Adventure R 20K miles, lived its life in the mountains and deserts of the western US.

    Has anyone at 20Kish miles just had the front calipers just quit / die. I changed a front tire yesterday and bolted the bike back up and it takes all my strength to turn the front wheel. I have made sure that the wheel / axle / fork is not binding, I am a reasonably competent mechanic.

    The caliper pistons will move out but will not retract at all, I assume this means something is going on in the caliper but thought I would ask before I tore into them. Anyone else seen this on these bikes ?

    Thanks
    #1
  2. kokos79

    kokos79 Nomad

    Joined:
    Apr 13, 2009
    Oddometer:
    1,535
    Location:
    Greece
    Did you follow the procedure in the manual? Cannot be simply a coincidence that the problem appeared after removing/reinstalling wheel and calipers

    This is from the 1090 manual but it's the same.

    Screenshot_20190622-195743_Adobe Acrobat.jpg
    #2
    Lewilewi likes this.
  3. tr0yy

    tr0yy Been here awhile

    Joined:
    Jan 13, 2013
    Oddometer:
    195
    Location:
    in the wind
    Well I thought I had, but I did do one step out of order. I will be at the shop shortly and will try again, Hopefully I learn something. I will report back upon my hopeful sucess or sad failure.
    #3
  4. kokos79

    kokos79 Nomad

    Joined:
    Apr 13, 2009
    Oddometer:
    1,535
    Location:
    Greece
    Did you by any chance install an aftermarket brake lever?
    #4
  5. Saltboxlad

    Saltboxlad Long timer

    Joined:
    Jan 13, 2015
    Oddometer:
    2,855
    Location:
    Wales, UK
    OP says at beginning pistons wont push back, if that is the case no option really but to overhaul calipers, its normally the outer dust seal that causes the issue, crud gets behind it and deforms the seal which then grabs the piston
    #5
  6. usgser

    usgser Long timer

    Joined:
    Nov 6, 2005
    Oddometer:
    3,580
    Location:
    Westside WA
    Not a KTM specific guy but disc brakes are pretty much disc brakes. Sounds like you got crud binding the pucks to keep then from retracting. Maybe the calipers seriously worn and they're getting cocked/bound in the bore. Time to dive into the calipers and at least clean everything to spec and flush the system with fresh fluid.
    #6
  7. kokos79

    kokos79 Nomad

    Joined:
    Apr 13, 2009
    Oddometer:
    1,535
    Location:
    Greece
    Both calipers at the same time, and immediately after a wheel replacement? My bet is on missaligned calipers on forks.
    #7
    Lewilewi and KTM 1190advR like this.
  8. brianbrannon

    brianbrannon They'll ride up with wear

    Joined:
    Dec 15, 2009
    Oddometer:
    2,260
    Location:
    Denver, CO
    Changing a wheel doesn't make caliper piston seals go bad
    #8
    KTM 1190advR likes this.
  9. tr0yy

    tr0yy Been here awhile

    Joined:
    Jan 13, 2013
    Oddometer:
    195
    Location:
    in the wind
    Ok I am an idiot, I put the wheel in backwards and just didn't notice it . Maybe to help someone else I'll fess up and not delete this thread. Thanks for the help and suggestions !
    #9
    TheBritAbroad and NorthBayPete like this.
  10. Wodger63

    Wodger63 Long timer

    Joined:
    Oct 30, 2011
    Oddometer:
    3,473
    Location:
    Hervey Bay
    The wheel will go in either orientation (abs ring makes no difference), it's the spacers interaction with the axle which give the correct offset.
    #10
  11. tr0yy

    tr0yy Been here awhile

    Joined:
    Jan 13, 2013
    Oddometer:
    195
    Location:
    in the wind
    Actually I had the spacers in the correct positions, small on the non threaded end of axle and large on the other, and there is an offset, its tiny but there...
    #11
  12. Wodger63

    Wodger63 Long timer

    Joined:
    Oct 30, 2011
    Oddometer:
    3,473
    Location:
    Hervey Bay
    I stand corrected, It must of been the FaBa hub I measured before installing that is non directional, it came with different spacers.
    I just checked my spare OEM front and there is about 3mm difference left to right.
    #12
  13. KTM 1190advR

    KTM 1190advR Enema of the state Supporter

    Joined:
    Aug 2, 2015
    Oddometer:
    3,340
    Location:
    Somewhere in Norway
    What I learned from this is I won’t write "reasonably competent mechanic" before I’ve ruled out being a possibly incompetent mechanic...:lol3
    #13
  14. Lewilewi

    Lewilewi Ride it like you stole it......

    Joined:
    Oct 22, 2017
    Oddometer:
    2,892
    Location:
    Europe
    Calipers /brakes can bind if wheel not correctly fitted the right way round with spacers correct...


    Even tho it may look correct at a glance, double check the wheels the correct way round
    #14
  15. slartidbartfast

    slartidbartfast Life is for good friends and great adventures Supporter

    Joined:
    Dec 23, 2003
    Oddometer:
    11,722
    Location:
    Southern Louisiana or Southern England or ...
    I think the OP already knows this :y0!
    #15
    brianbrannon and kokos79 like this.
  16. tr0yy

    tr0yy Been here awhile

    Joined:
    Jan 13, 2013
    Oddometer:
    195
    Location:
    in the wind
    At least I have the balls to admit I overlooked something, but then @KTM 1190advR is perfect.
    #16
    lithodave, Wodger63, orange M and 2 others like this.
  17. KTM 1190advR

    KTM 1190advR Enema of the state Supporter

    Joined:
    Aug 2, 2015
    Oddometer:
    3,340
    Location:
    Somewhere in Norway
    I didn’t mean to be rude but obviously that was how it came out, sorry for that...
    #17
    lithodave and Wodger63 like this.