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Sportster Motorcycle Tires, Wheels, and Brakes Discuss issues with Sportster motorcycle tires, wheels and brakes.

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  #1  
Old 4th May 2018
dayypete dayypete is offline
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Cool Rear brake pad pin being cut by rotor

Hello all, hope I can get some ideas. I recently replaced rear brake hoses, pads on a 2009 XL 1200C. Put it all back together and rode for a month. Recently went to replace rear tire and rear wheel bearings and noticed that there is a groove cut in the pad pin by the rotor. I can move the caliper around by hand and get the pin to sit right on the rotor.
Any ideas as to what is worn or put together wrong?
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  #2  
Old 4th May 2018
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You mean the rotor edge is kissing the pin?

Is the caliper mounting arm moving on the axle?
Or just the caliper itself is moving?
Moving forward & backward?

Did you disassemble the caliper when changing hoses & pads?
Did you remove it from the mounting arm?
How many miles on the bike?

The distance from the axle to the caliper is fixed by the caliper mounting arm - It shouldn't be changing...

Here's the parts diagram:
http://partsfinder.onlinemicrofiche....20REAR%20(CAST)

(ETA: Wrong Page - SLD posted the right one below...)

If you had the caliper off, did you get the bushing back right (item #2 in the diagram)?

Are the wheel bearings totally shot allowing the wheel to get closer to the caliper?

Have you done anything else to the rear wheel / brake / axle any time beforehand?

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Last edited by IXL2Relax; 11th May 2018 at 02:12..
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  #3  
Old 5th May 2018
dayypete dayypete is offline
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Yes, rotor edge is contacting pad pin and cutting into it. The caliper is moving around enough on its mounting pins so that the rotor has partially cut into the pad pin. The bike has 35k. The wheel bearings were just replaced but in test ride, I can see that has not fixed the problem.
Caliper mounting arm not moving. The caliper mounting pins and receivers on the caliper have a lot of slop in them. As mounted, I can move the caliper around enough to bring pad pin in contact with rotor. The caliper was not removed while I was replacing the hoses, pads. The caliper has not been disassembled. When I disassembled for tire, wheel bearings, I noticed the cut in the pad pin.
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Old 5th May 2018
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The diagram shows rear wheel, 2 is washer for belt pulley. This event began when I replaced brake hoses, pads. It became apparent to me when I disassembled the rear to replace tires, wheel bearings. On trying to reinstall rear wheel, I decided to make more room by removing brake pads and at that time I noticed the groove cut in the pad pin.
I did not remove belt pulley, nor brake disk to do the work and the spacers are aligned correctly and in place. I test rode the bike and all is well except that the caliper is set so that the pad pin contacts the rotor. A groove has been cut in the pad pin. Looking in the manual it talks about measuring the depth of this and replacing the pad pin if necessary. This surprises me in that the bracket assembly for rear caliper should never allow the pad pin to come in to contact with the rotor. Is something misaligned, does anyone have experience with this?
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Old 5th May 2018
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This link should show the brake caliper diagram, or you can easily navigate from the link IXL2Relax provided using the left pane.

I'm at work right now, so I can only go by the diagram and memory, so my thinking may not be correct with all this...

In this diagram, you are indicating pin #9 is contacting the rotor? Does seem odd. I would be checking bolt pins #13 and #14 for odd/excessive wear (they are what locate the caliper to the bracket), as well as the rubber bushing/boot that they go through (#2 & #3). Be careful with #14, it's not uncommon to strip the threads if things aren't lined up correctly. Wonder if that's maybe what could be wrong?
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Old 5th May 2018
dayypete dayypete is offline
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In the diagram Brake-rear brake caliper assembly, excessive wear on pin bolts, 13, 14 or their receivers is allowing the caliper to move around and pad pin, #9 is coming in contact with the rotor. I am going to see if the caliper, etc can be rebuilt. I understand the pin bolts can be replaced but if the bushing they seat in to is worn, I do not know if that can be replaced. Also ordered new caliper assembly and bracket. Right now that is where I am at. Thanks for your help.
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Old 17th May 2018
dayypete dayypete is offline
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I ended up installing new caliper assembly and all is well.
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