OK, I see how that goes but I just can't get them spread apart enough for the sprocket thing to fitbetween the pads. The first pad is tucked in nice but the outer pad just keeps falling out!!!!! I'm trying to squeeze the caliper out so I can fit the sprocket thing in,,BUT it aint gonna happen!!!!!!

MAN did I royaly SCREW myself today!!!!!!!!

I just can't seem to put this tire back on and in NO WAY do I want to concede failure but at this point I'm at a loss......unless I'm supposed to bleed something, remove the caliper or something that will
#1 allow the pad to stay put and #2 allow enough space so the shinny wheel sprocket thing can fit.....I'm DONE!!!!!
You guys have been a great help and I wish I had a mechanic friend, cause I'm gonna HATE bringing this bike back to the dealer in pieces!!!!

Thanks--
Dave
Nobody had any of these problems while putting the front wheel back on?? I'll admit to being a moron, but I thought it was straight forward and I had enough skill to at least do this!!!!

 

I've done lots of disk brake replacements on cars, and the principle is the same. I bet what happened is that either the brake lever was accidentally touched which pushed out the pad, and since the rotor wasn't there to stop the pad from coming out too far, it .......came out too far. Here is what you do. Take off the front brake reservoir cap off up by the lever, and then with the tire back off out of the way, take a pair of channel locks and adjust them to the right position and squeeze in the piston as far as you can, but be careful not to do it too fast, otherwise you are going to get brake fluid all over the place. Then after you get it back in then install the tire making sure the rotor is in between the pads. then bolt everything back up and tighten the reservoir cap and you're golden. If you need further assistance don't hesitate to IM me if you have it. derickettel@hotmail.com or at Aim deej1914

 

It's not necessary to remove the top to the master cylinder. Just push the pistion side back into the caliper and you will gain enough room to slide the rotor in. If you remove the master cylinder top you will more than likely push the piston too far in and you will definately have a fluid spill.

 

Man, I've tried everything under the sun to get this darn rotor into the caliper....................

I HAVE to be doing something wrong!!!!

#1 what keeps the inner pad held in place??? It just falls.....

#2 I push and push but the caliper only goes in so far, not enough for the rotor to fit...............

Please guys, one last ditch effort here before I just go completley insane!!!!!!![:@]
walk me through it like baby steps!!!!!!!!

 

OK, sounds like all you did was pull the front break leaver in while the front brake disk was not in place. I would think that what VFR Pilot suggested would work, if not, use Deejs suggestion as a very last resort since you'll quite likely get brake fluid all over AND need to add some, bleed the breaks etc...

Which break pad is falling off?? the one on the inside that just has a bar next to it or the one on the outside that is attached to the caliper (larger metal part of the brake system)?

Sounds like its the inside one, next to the smaller bar. If thats the case, swing it back up and put the notch into the little shiny clip (brake wear clip) that should hold it in place.

Don't pull on the brake leaver up on the handlebar until your sure that the break disk is correctly in between the break pads. Thats all you did, should not be hard to recover. Just take your time....

 

As Deej said, it's only a matter of pushing the pistons -both of them- back into the calipers. They don't push back in super easy. I normally use a C-clamp to do it, but don't know if one will fit on this caliper.

 

WHy OH WHy is this the hardest thing I've ever done???????
I spent 4 years on an AirCraft Carrier, 10yrs as a Firefighter and yet this PISTON CALIPER ROTOR thing is kicking my ***!!!!!!!!!!!!!!!

Here is a pic to show where I'm at,,,,,hope it helps you.. help me!!!!!!!!!!!!

[IMG]local://upfiles/3747/FF94ECBFE96E4CD2A80322C4F197DB77.jpg[/IMG]

That's as far apart as it will go........and the pad isn't clipping into anything!!!!

You guys are great for helping me, but I just poured a gallon of gas on her and set it a BLAZE!!!

 

See that little shiny clip up on the top of where the brake pad ends are (when you swing the pad up)? If you look at the pad that is pushed in (very well i might add) into the caliper, the top of that pad (which also has a notch) is resting comfortably on that clip. If you were to pull that pad out, it would move over to the middle of the clip where there is a space, then fall through and you'd have two pads swinging. (thats how you remove them for replacement so thats a good thing)

Move the lose pad so its in the middle of the bolt that its attached to and swing it up so that it goes into the grove in that clip. Push it back and then move the top and bottom of the pad over at the same time until you get the pad all the way back over where you want it. The clip will hold it in place..Thats where is was before you moved it forward and it fell through the slot in the clip...

Try that first.....

 

Man that's a good quality picture, I opened it up with Microsoft Office Picture Manager and I could enlarge it way up close and it didn't get distorted at all. Now you have a pad hanging down, and there is something on the inside of the caliper that has 3-4 groves in it. Is the pad that is hanging down the one that you are having trouble with? Here is a hopefully larger picture, for others to look at, we'll get this thing figured out, don't get frustrated. By the way what is the plate with the groves in it? Is that the other pad?

 

I keep running back and forth from the garage to the laptop,.....wait its wireless I should just take it to the bench....oh well. From what I can tell there is a clip for the pad after it gets put into place, I think you have to pull the clip out, put the pad up and then slide the clip in. Come on guys there must be someone here that has done this. The clip didn't fall out did it?