Disc Brakes of 2-Wheelers -Problems & Solutions !!!

madhokritesh · 3rd January 2009, 16:41

Hi, the disc brake on my RXZ 5speed are jammed, was rideing yesterday when i suddenly noticed a drop in pickup and then the front tyre got jammed. got the mech he took it to his workshop and opened it and cleaned and refitted it, but still the front wheel isent free enuff, its rotating in a restricted way, the wheel dosent even take a full round when pused with the front tyre up. any inputs from disc brake gurus or Yamaha RXZ owners?

madhokritesh · 3rd January 2009, 16:58

Waiting for Inputs as the bike is still at the mechs I dident accept it as the front wheel isent rotating freely.

dinar · 3rd January 2009, 17:04

bleed the brake and also check for the return spring in the caliper and the mater cylinder, once the system gets old these loose their properties.

white_vdi · 3rd January 2009, 17:05

madhokritesh can you hear the pads touching the disc while rotating it with hand? if yes then just ask him to adjust the disc pads and bleed the brake. that should solve your problem.

madhokritesh · 3rd January 2009, 17:35

Is the return spring for the RXZ Discs available??

Sankar · 3rd January 2009, 19:53

Get the caliper serviced. The piston might have corroded resulting in it getting stuck in the caliper instead of retracting back. Afaik ther aint no return spring inside the caliper.

madhokritesh · 4th January 2009, 12:42

Just got back from my mech, he says that the Discbrake needs a new set of O-ring, as there is no compression in it due to the old O Ring and thats why the pads are jamming the Disc. Any inputs guys???

Sankar · 4th January 2009, 12:48

Get the o-rings changed and the caliper piston checked for corrosion and clean if necessary. Nothing to worry about this is routine caliper servicing procedures.

And insist on replacing the old brake fluid in the complete system with new brake fluid from a sealed container. Don't forget to bleed the system properly.

madhokritesh · 4th January 2009, 12:54

The O Rings are not available for the RXZ, any replacement ones known??

Sankar · 4th January 2009, 13:08

That news is not good man. For Pulsars the caliper overhaul kit is available which contains the O-rings. Take your o-ring and see if another bike's matches it, try pulsar's first.

madhokritesh · 4th January 2009, 13:30

The mech said its different rightaway or he wud have replaced it with the Pulsars, Now what? the tyre is rotating but not freely and am scared it may get totally jammed as it did the other day and I may have a fall.

madhokritesh · 4th January 2009, 14:35

Can anyone get me a Disc Brake Overhaul kit for Yamaha RXz or provide links as to where i can get it from.

chiragh_bir · 4th January 2009, 16:09

try gladiator's or R15 ..

pjbiju · 18th March 2011, 14:25

In Pune does anyone know where I can get the caliper rebuild kit for Bajaj Pulsar? How much does that cost? One of the pistons of my front disc brake is jammed. I need to try and rebuild it. A new KBX caliper costs Rs. 1275 as quoted by mechanics. The rebuild kit with the O-ring and dust cover should be very cheap. And I have already bought a bottle of Dot-3 brake fluid for Rs. 40.

Manoj2268 · 18th March 2011, 15:10

Ask for 'minor kit - brake caliper'

Part no. DE 1510 51

It contains the Oil and dust seals, bleeder cap, dust cover and insulator. If you also want to replace the pistons , then ask for 'major kit - brake caliper' (DE 1510 52)

3rd January 2009, 16:41	#1
madhokritesh BHPian Join Date: Apr 2006 Location: Thane Posts: 334 Thanked: 4 Times	Disc Brakes of 2-Wheelers -Problems & Solutions !!! Hi, the disc brake on my RXZ 5speed are jammed, was rideing yesterday when i suddenly noticed a drop in pickup and then the front tyre got jammed. got the mech he took it to his workshop and opened it and cleaned and refitted it, but still the front wheel isent free enuff, its rotating in a restricted way, the wheel dosent even take a full round when pused with the front tyre up. any inputs from disc brake gurus or Yamaha RXZ owners?
	() Thanks

3rd January 2009, 16:58	#2
madhokritesh BHPian Join Date: Apr 2006 Location: Thane Posts: 334 Thanked: 4 Times	Waiting for Inputs as the bike is still at the mechs I dident accept it as the front wheel isent rotating freely.
	() Thanks

3rd January 2009, 17:04	#3
dinar Senior - BHPian Join Date: Mar 2006 Location: goa Posts: 1,066 Thanked: 57 Times	bleed the brake and also check for the return spring in the caliper and the mater cylinder, once the system gets old these loose their properties.
	() Thanks

3rd January 2009, 17:05	#4
white_vdi BHPian Join Date: Sep 2008 Location: new delhi Posts: 857 Thanked: 38 Times View My Garage	madhokritesh can you hear the pads touching the disc while rotating it with hand? if yes then just ask him to adjust the disc pads and bleed the brake. that should solve your problem.
	() Thanks

3rd January 2009, 17:35	#5
madhokritesh BHPian Join Date: Apr 2006 Location: Thane Posts: 334 Thanked: 4 Times	Is the return spring for the RXZ Discs available??
	() Thanks

3rd January 2009, 19:53	#6
Sankar Senior - BHPian Join Date: May 2005 Location: Location Posts: 5,766 Thanked: 9,054 Times	Get the caliper serviced. The piston might have corroded resulting in it getting stuck in the caliper instead of retracting back. Afaik ther aint no return spring inside the caliper.
	() Thanks

4th January 2009, 12:42	#7
madhokritesh BHPian Join Date: Apr 2006 Location: Thane Posts: 334 Thanked: 4 Times	Just got back from my mech, he says that the Discbrake needs a new set of O-ring, as there is no compression in it due to the old O Ring and thats why the pads are jamming the Disc. Any inputs guys???
	() Thanks

4th January 2009, 12:48	#8
Sankar Senior - BHPian Join Date: May 2005 Location: Location Posts: 5,766 Thanked: 9,054 Times	Get the o-rings changed and the caliper piston checked for corrosion and clean if necessary. Nothing to worry about this is routine caliper servicing procedures. And insist on replacing the old brake fluid in the complete system with new brake fluid from a sealed container. Don't forget to bleed the system properly. Last edited by Sankar : 4th January 2009 at 12:50.
	() Thanks

4th January 2009, 12:54	#9
madhokritesh BHPian Join Date: Apr 2006 Location: Thane Posts: 334 Thanked: 4 Times	The O Rings are not available for the RXZ, any replacement ones known??
	() Thanks

4th January 2009, 13:08	#10
Sankar Senior - BHPian Join Date: May 2005 Location: Location Posts: 5,766 Thanked: 9,054 Times	That news is not good man. For Pulsars the caliper overhaul kit is available which contains the O-rings. Take your o-ring and see if another bike's matches it, try pulsar's first.
	() Thanks

4th January 2009, 13:30	#11
madhokritesh BHPian Join Date: Apr 2006 Location: Thane Posts: 334 Thanked: 4 Times	The mech said its different rightaway or he wud have replaced it with the Pulsars, Now what? the tyre is rotating but not freely and am scared it may get totally jammed as it did the other day and I may have a fall.
	() Thanks

4th January 2009, 14:35	#12
madhokritesh BHPian Join Date: Apr 2006 Location: Thane Posts: 334 Thanked: 4 Times	Can anyone get me a Disc Brake Overhaul kit for Yamaha RXz or provide links as to where i can get it from.
	() Thanks

4th January 2009, 16:09	#13
chiragh_bir Senior - BHPian Join Date: Dec 2004 Location: In front of you :P Posts: 1,123 Thanked: 74 Times View My Garage	try gladiator's or R15 ..
	() Thanks

18th March 2011, 14:25	#14
pjbiju Senior - BHPian Join Date: Apr 2006 Location: Pune Posts: 1,357 Thanked: 1,092 Times	re: Disc Brakes of 2-Wheelers -Problems & Solutions !!! In Pune does anyone know where I can get the caliper rebuild kit for Bajaj Pulsar? How much does that cost? One of the pistons of my front disc brake is jammed. I need to try and rebuild it. A new KBX caliper costs Rs. 1275 as quoted by mechanics. The rebuild kit with the O-ring and dust cover should be very cheap. And I have already bought a bottle of Dot-3 brake fluid for Rs. 40.
	() Thanks

18th March 2011, 15:10	#15
Manoj2268 BHPian Join Date: Jul 2008 Location: Delhi Posts: 302 Thanked: 436 Times	re: Disc Brakes of 2-Wheelers -Problems & Solutions !!! Ask for 'minor kit - brake caliper' Part no. DE 1510 51 It contains the Oil and dust seals, bleeder cap, dust cover and insulator. If you also want to replace the pistons , then ask for 'major kit - brake caliper' (DE 1510 52)
	() Thanks