Rear brake pads too thick to fit? - BMW Luxury Touring Community
 
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post #1 of 14 Old Mar 6th, 2010, 12:08 pm Thread Starter
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Unhappy Rear brake pads too thick to fit?

Hi guys. I'm changing the rear brake pads on my '99 LT for the first time and got real BMW ones from the local dealer, who has my reg. number, chassis number, etc., so they should be right. The pads I am taking off are right at (and perhaps slightly beyond) the wear limit.

So, I've taken the calliper off the rear drive unit and taken out the old pads. The pistons are not right back in their cylinders, but are sticking out by 1.5mm at most. When I put the new pads in, there is no gap whatsoever between them, which is going to make getting them onto the brake disk somewhat of a problem. I don't have BMW's special tool for resetting the pistons, but even if I did, I'd only gain two or three mm and that still isn't going to accommodate a 7mm+ disk.

When I get my digital callipers on the pads and measure their combined thickness, then measure between the ends of the cylinders I only get a difference of 4.5mm and my disk is 7mm+ thick. At least one of the pistons is so loose that I am sure it is back as far as it can go and it still protrudes from the cylinder by at least 0.5mm.

Has anyone had this sort of problem before? Am I being dumb or is it possible that the pads I've been given are wrong? Can you get thin pads and thick ones (or am I being thick?)? Does anyone have any idea how much pad material there should be on the pads? They have the same part number stamped into them, but perhaps that is for the pad back plate only. My new pads have a part number printed on them, but the same number is worn off my old pads so I can't compare that.

Anyone got any ideas?

Thanks!

2004 BMW K1200LT Blue (Derek)
1999 BMW K1200LT Champagne (George, ret'd to the seaside)
1976 Honda CB400F Maroon (The Beauty)
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post #2 of 14 Old Mar 6th, 2010, 12:18 pm
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Re: Rear brake pads too thick to fit?

Those pads are used on a number of bikes so I'm guessing they didn't give you the wrong ones, but it's a possibility. First get the pistons compressed as far back as you can so the brake pad backing plates are flush against caliper. If you can't get the backing plate to this location then you may be installing them incorrectly. I changed pads multiple times on all three of the LTs in my past and I seem to recall the rear being a tight fit so what you're experiencing isn't uncommon.

David Taylor
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post #3 of 14 Old Mar 6th, 2010, 5:45 pm
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Re: Rear brake pads too thick to fit?

You can lever the pistons back with the old pads. Correct PN for your pads is 34217680375 and it works on ALL K1200LT year models. Only the fronts changed over the years. They should just slide in easily.

John
2009 K1300GT Red Rocket
2009 R1200GS (Gone)
2005 K1200LT Ocean Blue Blue Wizard 110 K and counting...
2006 Bushtec Turbo+2 Spell
2004 330 Ci Convertable
K4AN

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But lack DE, MA, RI and CT with the 2005 LT

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post #4 of 14 Old Mar 6th, 2010, 10:56 pm
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Re: Rear brake pads too thick to fit?

Just changed mine a week ago. Didn't have the BMW compression tool so I used the "Rocket Ron Compression Tool".....a pair of channel lock pliers. Pads went over the rotor easy.

Rocket Ron


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post #5 of 14 Old Mar 7th, 2010, 3:46 am Thread Starter
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Talking Re: Rear brake pads too thick to fit?

Doh! It turns out that what I thought were the cylinders were actually he pistons themselves and what I thought were the pistons were only the plastic bits in the top of the pistons! Well, it wasn't like that on my CB400F when I change the disk pads fiver years ago ;-)

Once I'd figured that out and loosened the top on the fluid reservoir I was able to push the pistons back easily (as predicted by all) and lo and behold the pads slipped in and the calliper went back on without any problems.

Isn't learning a great thing. I won't make that mistake again :-)

Thanks for your input guys, now back to fitting the speedbleeders and flushing the system out in the minus three degree temperature here in County Durham this fine sunny morn.

I'd rather be riding than servicing the bike, but I'd rather do that than work for a living!

MB

2004 BMW K1200LT Blue (Derek)
1999 BMW K1200LT Champagne (George, ret'd to the seaside)
1976 Honda CB400F Maroon (The Beauty)
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post #6 of 14 Old Mar 7th, 2010, 4:25 am
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Cool Re: Rear brake pads too thick to fit?

Quote:
Originally Posted by mbenn42
Doh!

now back to fitting the speedbleeders and flushing the system out in the minus three degree temperature here in County Durham this fine sunny morn.

I'd rather be riding than servicing the bike, but I'd rather do that than work for a living!

MB
G'day Michael, Is that you standing besides George there in yer profile pix....just thinking that the weather backdrop looks ok for riding...hahahhah .....yeah right!!!

cheers

Phill
19XX BSA 125cc "racing" Bantam
1950 Sunbeam 500cc S7 Combo
19XX Royal Enfield 500 J2 combo
19XX BSA 500cc single B33
1960 Triumph 650cc Tiger 110
1970 Honda 750cc four K1
1975 Triumph Trident 750 triple
1978 XS1100E 1100cc "The Tardis" (ret)
1999 K1200LT "Beryl Beemer"

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post #7 of 14 Old Mar 7th, 2010, 5:44 am Thread Starter
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Thumbs up Re: Rear brake pads too thick to fit?

No Phil, that's the better half somewhere on the road to Fort William on the first day of our honeymoon! Is that you on the left in the white suit? Who's your funny looking mate?

Speedbleeders fitted, new fluid flushed through, brakes working just fine :-) On with the rest of the service...

Cheers!

2004 BMW K1200LT Blue (Derek)
1999 BMW K1200LT Champagne (George, ret'd to the seaside)
1976 Honda CB400F Maroon (The Beauty)
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post #8 of 14 Old Mar 7th, 2010, 6:35 am
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Re: Rear brake pads too thick to fit?

You know you don't have to take the rear calipers off an LT to change the rear brake pads!
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post #9 of 14 Old Mar 7th, 2010, 5:51 pm
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Re: Rear brake pads too thick to fit?

Don't mean to hijack this thread, but I have my rear caliper off, and in reading previous posts, I've come to find out that the 2 bolts that hold the caliper on are of different sizes. Is it readily apparent where they respectively fit, or is there some other sort of BMW black science to tell which one goes where? Thanks in advance....

I'd rather have a bottle in front of me, than a frontal lobobomy!
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post #10 of 14 Old Mar 7th, 2010, 7:37 pm
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Re: Rear brake pads too thick to fit?

Yup,


The one with the sloped shoulder is the rear most one(highest point) and the one with a regular shoulder and washer goes to the front (lowest point). They are not interchangable and can cause a draging brake if installed incorrectly

John
2009 K1300GT Red Rocket
2009 R1200GS (Gone)
2005 K1200LT Ocean Blue Blue Wizard 110 K and counting...
2006 Bushtec Turbo+2 Spell
2004 330 Ci Convertable
K4AN

Have ridden a Motorcycle in all 48
But lack DE, MA, RI and CT with the 2005 LT

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post #11 of 14 Old Mar 8th, 2010, 7:03 am
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Re: Rear brake pads too thick to fit?

That's why even the BEST mechanic should have a Clymer manual Priceless!

Rocket Ron


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post #12 of 14 Old Mar 8th, 2010, 9:43 am
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Re: Rear brake pads too thick to fit?

Thanks for the info John. You people here are all priceless!

I'd rather have a bottle in front of me, than a frontal lobobomy!
87 K100RS Tooling round town edition
01 K1200LT Luxo-Barge
83 Yamaha XJ Turbo Forced Air Futility
83 GPz 1100 Thrashed, Trashed & Crashed
74 Honda 500-4 Mad Max reincarnate
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post #13 of 14 Old Mar 8th, 2010, 5:33 pm
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Re: Rear brake pads too thick to fit?

Quote:
Originally Posted by jzeiler
Yup,


The one with the sloped shoulder is the rear most one(highest point) and the one with a regular shoulder and washer goes to the front (lowest point). They are not interchangable and can cause a draging brake if installed incorrectly

I see what you mean by the sloped shoulder. Both of the bolts have separate washers, is that correct or does the rearmost bolt not use a washer?

I'd rather have a bottle in front of me, than a frontal lobobomy!
87 K100RS Tooling round town edition
01 K1200LT Luxo-Barge
83 Yamaha XJ Turbo Forced Air Futility
83 GPz 1100 Thrashed, Trashed & Crashed
74 Honda 500-4 Mad Max reincarnate
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post #14 of 14 Old Mar 8th, 2010, 10:47 pm
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Re: Rear brake pads too thick to fit?

The front one uses a washer, the rear one does not as the shoulder acts as a washer. Some one must have put one on it.

John
2009 K1300GT Red Rocket
2009 R1200GS (Gone)
2005 K1200LT Ocean Blue Blue Wizard 110 K and counting...
2006 Bushtec Turbo+2 Spell
2004 330 Ci Convertable
K4AN

Have ridden a Motorcycle in all 48
But lack DE, MA, RI and CT with the 2005 LT

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