Struggling with ATE brake job

[RonKMiller]

I've got everything remounted and pretty well snugged down but not torqued - and this just does not look right...

I should have taken pictures before taking it apart... :banghead

Do I have my legs swapped? - it seems there is ONLY one way to mount them according to the fiche drawings - with the axle bolt entering from the larger hole on the right side (looking at the front of the bike) with spacer and nut on the left.

I've messed up something.... :scratch

This picture is from the rider's view looking at the left caliper - the right looks the same - it seems like the black "slider puck" (for lack of a better term) should be underneath the flange - instead of poking out this far...

[mneblett]

I've got everything remounted and pretty well snugged down but not torqued - and this just does not look right...

I should have taken pictures before taking it apart... :banghead

Do I have my forks swapped? - it seems there is ONLY one way to mount them according to the fiche drawings - with the axle bolt entering from the larger hole on the right side (looking at the front of the bike) with spacer and nut on the left.

I've messed up something.... :scratch

This picture is from the rider's view looking at the left caliper - the right looks the same:
Ron, I'm trying to figure out what's wrong in that pic -- the caliper is in the right place, the fork lower is on the correct side -- what am I missing?

BTW, do you need the procedure for correctly aligning the caliper relative to the disc (using the eccentric pin that the caliper rotates upon)?

[mneblett]

Your pic reminded me of something I've been meaning to ask:

Are those the original snowflake wheels on the bike?

The reason for the Q:

A couple years after the snowflakes were introduced, BMW had a *massive* recall campaign, replacing basically every snowflake made up to X date due to potential problems with cracking/fracture/failure. The wheels were replaced free with snowflakes with slightly thicker reinforcements in key areas. I believe that recall is still active, and 30 years later you can still walk into a BMW dealer and they'll order/install a new set of the "safe" snowflakes. Your bike is old enough to easily fall within the recall years.

[20774]

it seems like the black "slider puck" (for lack of a better term) should be underneath the flange - instead of poking out this far...

Ron -

Yes, that black slider puck is supposed to ride on the ledge on the bottom of the fork slider. This lets the caliper slide in and out during actuation of the brakes and as the pads wear.

[mneblett]

Ron -

Yes, that black slider puck is supposed to ride on the ledge on the bottom of the fork slider. This lets the caliper slide in and out during actuation of the brakes and as the pads wear.

Is there a corresponding black puck on the opposite surface of the caliper? If not, then obviously, the calipers are reversed left/right. If there's a black button on both top and bottom of the caliper, I'm still not seeing the problem.

[20774]

Your bike is old enough to easily fall within the recall years.

Mark -

You can see the extra webbing along the "spokes" so this is a correct wheel...it doesn't need to be replaced.

Here's a good page showing the differences:

http://robfrankham.co.uk/bike/dreaded_bmw_front_wheel_recall.htm

[Barron_Williams]

My bike is not the same as yours, but I do have have dual discs with ATE calipers.

On my bike, the slider "pucks" are not visible.

I'm sorry that I don't have much else to offer, but it is hard to tell from the picture what might be incorrectly assembled.

Could you have the brake pads backwards, that is, the thick/thin parts reversed?

The final adjustment with the concentric bolt will move the caliper some, but I don't think enough to pull the puck under the fork flange.

Barron

[mneblett]

Mark -

You can see the extra webbing along the "spokes" so this is a correct wheel...it doesn't need to be replaced.

Here's a good page showing the differences:

http://robfrankham.co.uk/bike/dreaded_bmw_front_wheel_recall.htm
Thanks Kurt -- I didn't have a pic to show the difference. While I wasn't that worried about Ron, I thought it would be a shame to let such a nice airhead get hurt if a wheel collapsed! :thumb :laugh

[RonKMiller]

Your pic reminded me of something I've been meaning to ask:

Are those the original snowflake wheels on the bike?

The reason for the Q:

A couple years after the snowflakes were introduced, BMW had a *massive* recall campaign, replacing basically every snowflake made up to X date due to potential problems with cracking/fracture/failure. The wheels were replaced free with snowflakes with slightly thicker reinforcements in key areas. I believe that recall is still active, and 30 years later you can still walk into a BMW dealer and they'll order/install a new set of the "safe" snowflakes. Your bike is old enough to easily fall within the recall years.

Yah, many thanks for that heads up - something I was aware of prior to the purchase and it was replaced many years ago with the reinforced version.

[RonKMiller]

Thanks all!

I've definitely got something back***wards! :dunno

The fiche is always helpful for me, but I can't make out much from the drawings - more pictures to follow, this is of the left side...

[RonKMiller]

and another...

[RonKMiller]

juan mo time...

[RonKMiller]

I am SO confused...:eek

[RonKMiller]

Thanks Kurt -- I didn't have a pic to show the difference. While I wasn't that worried about Ron, I thought it would be a shame to let such a nice airhead get hurt if a wheel collapsed! :thumb :laugh

Hey, I resemble that comment! :nyah :thumb

[RonKMiller]

My bike is not the same as yours, but I do have have dual discs with ATE calipers.

On my bike, the slider "pucks" are not visible.

I'm sorry that I don't have much else to offer, but it is hard to tell from the picture what might be incorrectly assembled.

Could you have the brake pads backwards, that is, the thick/thin parts reversed?

The final adjustment with the concentric bolt will move the caliper some, but I don't think enough to pull the puck under the fork flange.

Barron

Yah, everything spins freely, the brake pads are aligned correctly, etc. It just does not look right, that's why I thought maybe I had the fork legs reversed.

Sigh, things were going so well... just getting ready to put some fluid in and align the E-pins for maximum leverage.

Perhaps you could give the factory a ring for me. :wave

[rocketman]

On my 78 the flange on the fork leg above and below the caliper faces IN TOWARD the wheel, not OUTWARD and therefore makes seeing the outside puck and shoe much harder than in your pics.

When FACING the bike from the front the axle on my single disk R100 goes in from the right and the nut is on the left. I think you have your lower fork legs reversed assuming the twin disk fork legs arrangement is the same.

RM

[crazydrummerdude]

the flange on the fork leg above and below the caliper faces IN TOWARD the wheel, not OUTWARD

Mine, too!

[mneblett]

Ron, this may be yet another "duh!" comment from me, but in the second pic above, the lower outside face of the fork leg has an "R" written in pen on it -- looks like you gave yourself a hint when you were working on it.:D

[rocketman]

see pic, where the red line is is where the flange on my fork leg is, opposite the direction yours is facing (flange outlined in black).
Not sure of the function of the flange, perhaps to protect the shoes from getting hit by road debris but that is who it is on my single disk ATE.

RM

[tghsmith]

I just noticed the "RL" that is written on the slider that on the left... we've all been there... last weekend I rebuilt the carb on my chainsaw because it wouldn't start, cleaned the carb again because it still wouldn't start, pulled that dam cord way to many times, then I cleaned the spark arrestor(three minute job) started the next pull ,, "DOH!"

[rocketman]

I just noticed the "RL" that is written on the slider that on the left... we've all been there... last weekend I rebuilt the carb on my chainsaw because it wouldn't start, cleaned the carb again because it still wouldn't start, pulled that dam cord way to many times, then I cleaned the spark arrestor(three minute job) started the next pull ,, "DOH!"

and the axle is going in from the wrong side, into the right leg which is right when on the right side, but wrong when on the left!

I believe this mystery is solved!

RM

[20774]

Hey, I think that the problem is not the calipers...but it's the fork legs...you have them switched left vs right! Does that make sense? That little "shelf" above and below is what the black sliders move across. If you moved the fork sliders side to side, that "shelf" would be pointing towards the wheel rather than away from it. I think that's the issue...

Oooops...looks like everyone else jumped on that...I didn't read through all the posts...

[RonKMiller]

I am officially awarding myself the title of "Idiot of the Week". :banghead

I WROTE "RI" for right, inside on the leg when I took it apart over a month ago to remind me what side it goes on when I reinstalled, but it took Mark to see it in the picture, which was nicely illuminated with the flash - but barely visible in ambient light!

Oh well, at least I didn't put any fluid in it yet, perhaps it is time to take a deep breath and put a little fluid in ME. :drink

Thanks again everyone, where else in the world can you get this kind of response to my REALLY dumb question?

Surely, there are more to come. :blush

[toooldtocare]

I am officially awarding myself the title of "Idiot of the Week".

Oh well, at least I didn't put any fluid in it yet, perhaps it is time to take a deep breath and put a little fluid in ME. :drink

Thank goodness, my head was starting to hurt. :bikes

[PGlaves]

I am officially awarding myself the title of "Idiot of the Week". :banghead

I WROTE "RI" for right, inside on the leg when I took it apart over a month ago to remind me what side it goes on when I reinstalled, but it took Mark to see it in the picture, which was nicely illuminated with the flash - but barely visible in ambient light!

Oh well, at least I didn't put any fluid in it yet, perhaps it is time to take a deep breath and put a little fluid in ME. :drink

Thanks again everyone, where else in the world can you get this kind of response to my REALLY dumb question?

Surely, there are more to come. :blush

No. You knew it "didn't look right". You stopped. You asked questions. And it got sorted out. Kudos for recognizing something looked wrong. That in itself is a huge achievement, believe me!

[Radar41]

I am officially awarding myself the title of "Idiot of the Week". :banghead

I WROTE "RI" for right, inside on the leg when I took it apart over a month ago to remind me what side it goes on when I reinstalled, but it took Mark to see it in the picture, which was nicely illuminated with the flash - but barely visible in ambient light!

Oh well, at least I didn't put any fluid in it yet, perhaps it is time to take a deep breath and put a little fluid in ME. :drink

Thanks again everyone, where else in the world can you get this kind of response to my REALLY dumb question?

Surely, there are more to come. :blush

Ron,

It does not count against you if you find the mistake BEFORE any damage is done. I've had techs who would screw things up THEN ask for help!! You "did good" :)

Like Mr. Paul said, you stopped, analyzed the problem and asked for help, the mark of a good technician!!