Front Caliper Problems

Front Caliper Problems
Posted by Andys92 on 17 Nov, 2012 14:37
I am about to throw this quad under a bus!!!
for some reason my front calipers don't line up anymore. i took them off and the hubs .cleaned them all checked the hub bearings (small amount of play) then put everything back together with new brake pads.Now they don't fit. looked over the clymer manual over and over again and just cannot see why this has happened.Could worn bearings and bearing dust caps be the issue? has anyone had this problem or is it just me not doing something correct .Should never of bought this friggin' thing as it is just sooo frustrating !!
any ideas anyone?suzukiquadracerhq

#2 Reply
Posted by Sublunacy on 17 Nov, 2012 16:32
This Im afraid is your quadracer now The difference between a novice and an attentive mechanical mind is worlds apart. goodluck< and let us know if you dont get it sorted.

Sounds like the hub bearing is not seated in all the way. an easy way to check that is to feel the bearing spacer and check if it seems sandwiched fully. I believe if you crank the spindle nut tight it should theoretically pull the bearings together squishing the spacer in tight and seat everything fully. correct?

Your factory calipers have two pionts that slide, side to side a bit. One is the piston. the second is the sliding bolts. The yfz450 calipers are the same technology/design but with dual pistons> not to be confused with opposing piston calipers wich have to work around different design and function. By the way those brakes your working with now are the identical design to 90% of the brakes on the road today.

#3 Reply
Posted by Dezsled on 17 Nov, 2012 16:42
http://partsfinder.onlinemicrofiche.com/hondaeasttoledo/Suzuki_OEM/SuzukiATV.asp?Type=13&A=159&B=30

Check parts 6,7&8

Did you relube the pins on #6 that go into #7&8?

#5 Reply
Posted by WestTexasKing on 17 Nov, 2012 18:41
Soooo....that's what happens when you install new pads, you've never changed brakes before?
Remove the pads and clamp down on the piston with a C-clamp until it's flush with the caliper, reassemble brakes and they should magically fit again :p

Don't worry, it happens to the best of us...we get so sidetracked thinking about how stuff works in other areas that we forget some of the most obvious stuff out there.

#8 Reply
Posted by Andys92 on 18 Nov, 2012 06:10
pistons are flush to the rubber that surround the pistons,but the rubber is not flush to the caliper.the same on both sides. but like i said they were the same both sides so i convinced myself this was how they should be .
Badmoon you may have answered this already but not sure if you were talking about the pistons alone. Should the rubber around the piston be flush.?

Thanks everyone and by the way i am not stupid (not really stupid anyway:) just getting incredibly frustrated with it and when that happens .........nothing is simple !!

#9 Reply
Posted by Sublunacy on 18 Nov, 2012 09:42
Does the caliper fit on the disk after sinking the pistons. [without the caliper mounted]

Did you replace the bearings[are they the same width?]

Does the physical mount on the caliper move in and out like it is supposed to?

#11 Reply
Posted by BadMoonRacing500 on 18 Nov, 2012 12:20
Quote from: WestTexasKing on 18 Nov, 2012 12:16
Did you get the right pads?
I was wondering the same thing. How close is it to fitting? PICS....

#13 Reply
Posted by Andys92 on 18 Nov, 2012 15:55
pads are correct and it all now fits. Problem was dust cap on both inner hubs were pushed in very slightly (along with bearings i guess)in , i assume from over tightening .combine that with small amount of rust and a lot of dirt in the surrounding piston rubber stopping it from compressing slightly was enough.It was all so minimal but together it was enough. sorry for asking such a simple and stupid question but after trying so many times to get it to fit i was just at my wits end.
thank you all for taking the time to reply i really appreciate it .