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post #1 of 17 Old Jun 13th, 2013, 5:43 am Thread Starter
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front disk

I have 90,000 miles on this bike (2002 lt). The front disk rattles a lot. I have added several wave washers but it's really loose. I think the main problem is that the metal is worn both on the roll pin and the disk. Which makes it impossible for the roll pin and wave washers to hold the disk stable. But I could sure use some advice. Am I on the right track and is there a fix other than replacing all the roll pins and the disk?

Michael L. Lempenau
85/41 Moo7, T.Nongjom, A.Sunsai
Chiang Mai, 50210, Thailand
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post #2 of 17 Old Jun 13th, 2013, 8:49 am
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Re: front disk

Did you mean the REAR disk...cause if it is the front it is a big problem.

John Baker

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post #3 of 17 Old Jun 13th, 2013, 11:14 am Thread Starter
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Re: front disk

It is the front --- so I need a new rim?

Michael L. Lempenau
85/41 Moo7, T.Nongjom, A.Sunsai
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post #4 of 17 Old Jun 13th, 2013, 12:56 pm
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Re: front disk

That is an unusual wear pattern that I have not seen here. The rotor should float but not rattle. Maybe a picture of the pin area could help. I take it when you say roll pin you mean item #4?
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John
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2005 K1200LT Ocean Blue Blue Wizard 110 K and counting...
2006 Bushtec Turbo+2 Spell
2004 330 Ci Convertable
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Have ridden a Motorcycle in all 48
But lack DE, MA, RI and CT with the 2005 LT

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post #5 of 17 Old Jun 13th, 2013, 3:52 pm
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Re: front disk

I think that is exactly what he means John, # 4

I had identical issue on my 2003, in taking it apart to examine, the pins were worn and the slot on disc also worn just a bit.
I needed a new tire and when the mechanic noticed he said that he can fix or I need new parts. I believe he tightenned everything down snug. Now there is no play on the right side disc and he demostrated how there is an ever slight rubbing on the brake shoe to one side now, but barely noticeable.
I have been riding it as is with no appearent negative reaction--though I suspect the brake shoe will wear out prematurely. I checked if the disc were to get hot from friction but it doesn't.
Am I in trouble?
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post #6 of 17 Old Jun 13th, 2013, 8:28 pm
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Re: front disk

Well in a caliper type brake system one item must "float". In most automobiles this is the caliper and the rotor is fixed. On the LT the caliper is fixed and the rotor floats. If you have the rotor locked down you will see more rapid wear of the pads and may even experience reduced braking force since the rotor is not free to float into optimal position.

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 #7 of 17 Old Jun 14th, 2013, 3:07 am Thread Starter
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Re: front disk

Over time I have notice the rotor become looser and looser. I have compensated by adding extra wave washers. But it's worn too much now. The rotor is moving around so much it is reshaping the roll pins (#4) and also the hole in the rotor. I don't have it apart right now to take a picture but I don't remember the rim having any problems.

I just looked again and it's the rotor and roll pins, not the rim that is the problem. Having come from the aircraft world, it looks to me like we should write a bulletin that tells people to replace the roll pins every 50,000 miles to avoid this.

I guess I will replace the roll pins and hope it's enough without having to replace the rotor too.

Any better ideas??

Michael L. Lempenau
85/41 Moo7, T.Nongjom, A.Sunsai
Chiang Mai, 50210, Thailand
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post #8 of 17 Old Jun 14th, 2013, 5:15 am
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Re: front disk

There is no wear on my pins at over 175,000 miles.

Dave Selvig
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post #9 of 17 Old Jun 14th, 2013, 5:28 am Thread Starter
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Re: front disk

So what's the problem?

I will admit that my left side is just fine and it has the same mileage. The only difference I can think of is that the right rotor is the one I always take off when I change a tire.

Michael L. Lempenau
85/41 Moo7, T.Nongjom, A.Sunsai
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post #10 of 17 Old Jun 14th, 2013, 8:24 am
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Re: front disk

full floating disks allow for expansion/contraction with heat/cold and that prevents warping with lighter thinner rotors, before full full floating rotors were a lot thicker

the opposing pistons in the caliper will adjust for where the rotor is

Gary
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post #11 of 17 Old Jun 14th, 2013, 10:03 am
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Re: front disk

Quote:
Originally Posted by mlempenau
So what's the problem?

I will admit that my left side is just fine and it has the same mileage. The only difference I can think of is that the right rotor is the one I always take off when I change a tire.

Maybe related to the removal and re-installation but I don't have an idea of the driver for that. Mine are tight as a drum at 78K but I never remove them. Might try finding a way to protect them when changing a tire so you don't have to pull it.

John
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2009 R1200GS (Gone)
2005 K1200LT Ocean Blue Blue Wizard 110 K and counting...
2006 Bushtec Turbo+2 Spell
2004 330 Ci Convertable
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Have ridden a Motorcycle in all 48
But lack DE, MA, RI and CT with the 2005 LT

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post #12 of 17 Old Jun 14th, 2013, 9:16 pm Thread Starter
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Re: front disk

What's the trick to changing a tire without taking the rotor off? Do the latest machines have the ability to do this?

Michael L. Lempenau
85/41 Moo7, T.Nongjom, A.Sunsai
Chiang Mai, 50210, Thailand
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post #13 of 17 Old Jun 15th, 2013, 12:16 pm
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Re: front disk

I use this old modified Harbor Freight unit and the rotor does not come close to anything. What are you using?
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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 #14 of 17 Old Jun 15th, 2013, 12:35 pm
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Re: front disk

Could it be that the front left side rotor has a sensor ring attached to it--thus it is fixed and does not float?
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post #15 of 17 Old Jun 15th, 2013, 5:35 pm
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Re: front disk

Nope the "roll pins" allow the rotor to float while holding the sensor ring in place.

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 #16 of 17 Old Jun 16th, 2013, 11:10 pm Thread Starter
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Re: front disk

Here in Thailand I just take it to a tire place and they use a machine. In the US I had an old machine I bought and used. It required me to take off the rotor so I guess I got in the habit. Do the new machines need the rotor taken off?

Michael L. Lempenau
85/41 Moo7, T.Nongjom, A.Sunsai
Chiang Mai, 50210, Thailand
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post #17 of 17 Old Jul 5th, 2015, 7:42 pm
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Re: front disk

Quote:
Originally Posted by mlempenau View Post
I have 90,000 miles on this bike (2002 lt). The front disk rattles a lot. I have added several wave washers but it's really loose. I think the main problem is that the metal is worn both on the roll pin and the disk. Which makes it impossible for the roll pin and wave washers to hold the disk stable. But I could sure use some advice. Am I on the right track and is there a fix other than replacing all the roll pins and the disk?
I bought a used 2007 after owning two 2002 KLT's and this front right rotor has more play than any of my others. Needless to say, it makes a "ticking" noise as I drive. I didn't have the problem until after I had the front tire replaced for the first time since I owned it. My dealer told me it was "normal" but after owning three LT's, I'm not convinced. Did replacing the roller pins illuminate the problem or did you come up with an easier fix?
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