Changing front brakes Fiasco!

[Dave Dark]

Hello All! Hope you're enjoying the weather and riding!

I'm in Ottawa so I'm down for the winter. I decided to do some maintenance on my bike - specifically change the front brake pads. It did not go well. Maybe someone can help me.

I followed the instructions exactly and got everything off. As I did the brake pads fell out. I cursed myself because I wanted to see how they were set up exactly.

I played around to fit them back into the caliper. I noticed that the brake pad mounting bolt should fit through the cut out circle on the brake pads. I thought this was ingenious. So simple and straight forward. I decided to put the mounting bolt through just to see if that was right. Now the bolt is back on BUT it is now stuck. I can't turn it back out.

Does anyone have any ideas how to get out a stuck in bolt? Am I going to have to drill it out? Do I just need more elbow grease?

As well, how do I know if the pads are sitting properly in the calipers?

Thanks in advance for all your help!

[jonathan180iq]

The pads really only sit in one way. If they are snug in there, you did it right.

As far as the bolt goes, did you cross thread it? Did it resist you while turning it in?
I can't see why it won't come out. Wiggle the caliper while you were pulling on it and see if for some reason it has a load on it.

http://images.cmsnl.com/img/partslists/front-caliper-gz250-1999-x_bigsue0367fig42_2f16.gif

[Dave Dark]

Thanks for responding jonathan180iq.

It could be cross-threaded but I part of me doesn't believe that it is. It didn't fight me going in but it did get slightly hard to turn which I feel is normal with bolts and screws.

I think it is my stupid allen keys. I used a standard type instead of metric and it was too small and it rounded the edges of the interior slightly. Now it slips and I can't get enough leverage.

I'm going to borrow a allen key ratchet set so I can get more leverage. Hopefully that will help. If I can get it out I think I will replace the bolt. If not I'll have to disconnect the calipers and take it to a licensed mechanic!!!

Thank god it is winter! First snowfall today. An end to biking here in Ottawa!

Dave

[alantf]

I'm going to borrow a allen key ratchet set

EVERYTHING on the GZ is metric. If you're going to work on it yourself you're going to have to get metric allen keys, wrenches, & a metric socket set. :)

[Water Warrior 2]

Xmas is coming. Tell everyone concerned to give you gift certificates from stores that sell tools. Much better than a box of chocolates or that ugly pair of socks.

[Dave Dark]

Just to give an update.

I bought a used caliper for 30$ on ebay. It was cheaper than buying the 47.95$ bolt.

I had a mechanic get the stuck bolt out and reassembled the caliper with the bolt I took from the ebay caliper.

I mounted everything back on. I will have to bleed the brakes because I did have to disconnect the brake line union hose.

Either way, new brake pads are installed. I'm hoping they last a REALLY long time.

Lesson Learned: 1) Don't crossthread - make sure you can fingertighten first 2) Use the correct size tool otherwise you screw things up 3) Invest in quality tools that will help you complete the job well and without to much fuss.

Thanks for all the help friends!

[Water Warrior 2]

47.95 for a bolt is criminal. I can see why you went with ebay.

[tallaghan]

If it's any consolation I have just done something similar yesterday, I have rounded the allen head. I will have to drill it out and buy a replacement bolt. It should not cost $47.95 though, look at www.powersportsplus.com (http://www.powersportsplus.com). The OEM part number is 59345-14600. Should not cost more than $10

[mrlmd1]

How'd the mechanic get the stuck bolt out while you couldn't? Did he just use the right size metric wrench or did he have another trick?

[OBryan]

A quick tip that I learned after rounding off a alen head.. Took to mechanic he grabbed a torx and tapped it in and voila backed out the bolt for me

[Rookie Rider]

That wont always work.

[OBryan]

If it does though a lil bit of saved money..If not it won't hurt anything to try.