Suzuki V-Strom (VStrom) Owners Club DL250, DL650, DL1000 & DL1050

V-Strom specific discussion => V-Strom specific discussion => Topic started by: Kobe on August 02, 2021, 18:45:25

Title: Rear brake assembly problems
Post by: Kobe on August 02, 2021, 18:45:25
Good evening everyone,
 Hope you are well. I am a proud owner of k5 650 Storm, but I have a bit of a problem. I am at the finish line of rebuilding brake callipers. I have two spacers left and I don't know why and where from. Also when mounting rear caliper I noticed that mounting bolt is going through everything until it hits the disc. There is no chance I can tight it up. I will attach the picture of spare spacers and bolt going through the brake. Thank you so much for any help.  :ty:

Kind regards,
 Tomas
Title: Re: Rear brake assembly problems
Post by: Kobe on August 02, 2021, 18:50:10
Can't add photos. Anyone know how to? Thank you :]
Title: Re: Rear brake assembly problems
Post by: kwackboy on August 02, 2021, 19:29:57
This is all that's involved in the rear brake set up as far as the caliper is concerned and how it should fit together.

The second, is one of the front calipers, they are both the same for illustration purposes.
Title: Re: Rear brake assembly problems
Post by: Kobe on August 02, 2021, 19:50:09
Hello Kwackboy,
 thank you for getting back to me. That's what I don't understand. Because the bolt number 9 on Rear brake picture is so long that it go through and is hitting the brake disc on rear wheel. I didn't noticed it when I took it off, but it seems too close to disc and yet I can't get it tight enough. Thank you for your help.
Title: Re: Rear brake assembly problems
Post by: Kobe on August 02, 2021, 19:54:23
https://ibb.co/DRwTP7d
That's the photo of the nut. Thank you.
Title: Re: Rear brake assembly problems
Post by: kwackboy on August 02, 2021, 20:12:37
Number 10 should be inside 11 and number 9 should go through number 10 and screwed into the hanger.

Maybe you have number 10 left over ?
Title: Re: Rear brake assembly problems
Post by: Kobe on August 02, 2021, 20:26:48
The spacers that I have left are not on any of the schemes you posted. I don't understand that, maybe I didn't spot it and it was like this before. Just the bolt wasn't screwed in all the way so it wasn't secure. Only think I can think of is to buy a same bolt just shorter thread.  :shrug:
Title: Re: Rear brake assembly problems
Post by: V-Twin on August 02, 2021, 20:29:14
Kobe. Have a look at the bolt & check the length.
Title: Re: Rear brake assembly problems
Post by: V-Twin on August 02, 2021, 20:30:22
Last picture, You have got the floating tube in there????
Title: Re: Rear brake assembly problems
Post by: Kobe on August 02, 2021, 20:48:46
Thank you for your photos. The bolt seems the same size, just the thread looks longer on mine. I snapped the last one. That's how I noticed something is wrong. I set torque wrench and kept going and snapped at the end. I took it to wee moto and I tried today and I think that's why it snapped. It couldn't go any further than disc. I have the floating tube in there. I am getting lost :D
Title: Re: Rear brake assembly problems
Post by: kwackboy on August 02, 2021, 21:04:43
Show us a picture of the parts you have left over ..
Title: Re: Rear brake assembly problems
Post by: Kobe on August 02, 2021, 21:23:18
https://ibb.co/PxJCPB3
That's the leftover spacers. But they maybe from something else, as I had it in the bag. I know not very clever.
Title: Re: Rear brake assembly problems
Post by: kwackboy on August 02, 2021, 21:38:44
What ever they are, they're nothing to do with the brakes ... :thumb:
Title: Re: Rear brake assembly problems
Post by: V-Twin on August 02, 2021, 21:42:18
Which all comes down to....show a picture of the bolt you broke.
Did you measure it, from under the head like I showed.
Have you measured the new bolt you have got?????
++++++++++++++++++++++++
Looking at the picture of the broken bolt, it looks the same as original.
I would at this stage presume you have some other problem that we can't see.
Maybe more pictures are called for...
Title: Re: Rear brake assembly problems
Post by: Kobe on August 02, 2021, 21:52:55
Here is the photo of the bolt the old one. The new one is exactly the same. We compared it in the shop with the salesman. https://ibb.co/bsNzYhX
Title: Re: Rear brake assembly problems
Post by: Rusty Nuts on August 02, 2021, 22:03:35
The unthreaded portion of your bolt looks shorter than that on vtwin's. If the overall length is the same, that would mean the threaded part is longer and would wind through the hanger and hit the disc before it could lock.
Title: Re: Rear brake assembly problems
Post by: V-Twin on August 02, 2021, 22:05:40
I would at this point remove the wheel & double check what you have done.
Wheel Spacers correct???
Caliper carrier in correct position?
Correct bolt in front pivot??
Title: Re: Rear brake assembly problems
Post by: kwackboy on August 02, 2021, 22:06:04
Don't worry about the tread length, as long as the bolt is the same length and you have assembled it the same as the diagram above, you shouldn't have a problem.

The only reason the bolt would foul the disc is either it's too long or you haven't used item number 10 in the diagram.

Post a picture of the rear caliper,zoom out a little, I need to see the whole thing,  with the said bolt fitted ...

Title: Re: Rear brake assembly problems
Post by: V-Twin on August 02, 2021, 22:09:12
Rusty, that wouldn't matter. It can only go in so far, then the bolt would bottom out on the spacer tube.

Thinking on Kobe, remove the spacer tube & check the length.
Title: Re: Rear brake assembly problems
Post by: Kobe on August 02, 2021, 22:24:52
I will have a look tomorrow and will post another photos if I wouldn't be able to do it. I will add one more photo I took. I don't think you would be able to see anything, but you never know. Thank you so much for your time and help V-Twin and Kwackboy!! Have a good night :]
https://ibb.co/QMnnZqT
Title: Re: Rear brake assembly problems
Post by: kwackboy on August 02, 2021, 22:43:55
If your spacer (item 10) hasn't been changed or modified and the aftermarket bolt is still fouling the disc , I'd say it's too long.
Title: Re: Rear brake assembly problems
Post by: Rusty Nuts on August 03, 2021, 06:39:56
Yeah, apologies for the red herring regarding thread length. I was looking at the bolt in isolation, rather than how it behaves when assembled. Oops.
Title: Re: Rear brake assembly problems
Post by: Keith60 on August 03, 2021, 08:02:01
Take the bolt out, put a nut on it, grind 5mm off the end of the bolt then take the nut off to ensure the thread isn’t damaged.  Job done.  That’ll cure it, what ever parts have been change previously. 
Title: Re: Rear brake assembly problems
Post by: V-Twin on August 03, 2021, 10:30:47
Quote removed

blokes, I think he has something assembled wrongly.
The Bolt looks like its the right size & length, after all that bolt came out originally.(the replacement bolt is correct too)
If the Spacer tube hasn't been removed, then too that means he has something wrong somewhere.
If you do cut the Bolt down, in my opinion that is the wrong thing to do.
Kobe needs to remove everything he did originally & start again.

Kobe, if you video the work as you do it you could always upload to youtube so we can see it, or send it to me. PM first.
Title: Re: Rear brake assembly problems
Post by: sillyboy on August 03, 2021, 15:35:44
the only problem I had was getting that







the only problem I had was getting that ******* no4 clip to stay in place.


Title: Re: Rear brake assembly problems
Post by: kwackboy on August 03, 2021, 19:26:07
This might sound a bit odd to some but,  you actually can't fit the whole rear brake assembly wrong, the parts don't fit any other way, not even the wheel spacers.

With everything in its correct place it all fits together,  if one part isn't in the right place it won't fit...  :shrug:

The picture I posted earlier is silly boys rear caliper and to me , it looks like it's fitted correctly  :shrug:

If the silver bolt is too long, it will foul the disc. 
Title: Re: Rear brake assembly problems
Post by: V-Twin on August 03, 2021, 19:54:10
Some more measurements for you to look at.
Title: Re: Rear brake assembly problems
Post by: Rusty Nuts on August 03, 2021, 20:34:19
That last pic is key. Kobe, do you have the tube (part no. 10)? Could you, as Vtwin has asked - a couple of times - post a pic of it with the bolt? How much bolt sticks out with the bolt head butted up to the end of the tube?
Title: Re: Rear brake assembly problems
Post by: kwackboy on August 03, 2021, 20:40:59
Just realised I got the names mixed up .. it's Kobe's picture not sillyboys ...  :whistle:
Title: Re: Rear brake assembly problems
Post by: V-Twin on August 03, 2021, 20:55:01
Just to let you know, that the set bolts thread protrudes 14mm out of the slider tube.
The ally caliper bracket is 14mm. And so, that is why when your bolt is fully tightened it will only show itself by 1mm at the most.
Also that is why the tread is further up than you think it should be. This allows the thread to tighten up on itself.
Effectively trapping the slider tube, so the caliper can move on the tube as the pads wear.
Title: Re: Rear brake assembly problems
Post by: Kobe on August 03, 2021, 23:13:26
Good evening,
 after checking the lenght of bolt in bike I found that it's longer about 3mm. After I checked invoice and it is bolt from Kawasaki. So I went back to the shop and asked if they have any other bolt, but they don't. So I will order an original bolt made by Suzuki and hopefully it will do the trick. I will keep you updated if I find anything elese. Have a good night everyone. :]
Title: Re: Rear brake assembly problems
Post by: kwackboy on August 04, 2021, 17:37:41
Glad you've discovered the problem  :thumb: