Front Brakes

[NewBoots]

The front brakes on my 1998 Calf. act like the rotors are warped. I have heard that the buttons on the rotors need cleaned. My guesting is how do you clean them?
Bucky 

[knockerjoe]

Give more info on why you think they are warped.Do you get a pulse feeling while braking?

[wirespokes]

I've cleaned up the discs on my 97 and the 87. Hopefully the 98 is the same?

Taking apart the holders (buttons, or whatever they're called) was actually pretty easy. They're held in with big snap rings - so a suitable snap ring pliers is needed. The tough part is removing the discs from the wheel. They're loctited in so you'll need to focus a propane torch on the heads to loosen them up. If you're careful, the paint won't be damaged. It can take a little while to get enough heat down to the end of the bolt. I found that working them back and forth instead of trying to muscle them out in one shot was the way to go. Use penetrating fluid, it helps.

[pehayes]

Yes, this was a classic and chronic issue with the 98EV because the discs and buttons were made with too tight a clearance.  Makes the hand lever pulse like a warped disc but it isn't.  It is just off angle and bound in that position.  Better brakes have nice, loose buttons and discs so this binding doesn't occur.

You can clean them in place without removing the disc from the wheel.  If the buttons have a hole through them then  you can just add a bolt and use that to slowly turn the button while you spray brake cleaner.  See here:

https://www.youtube.com/watch?v=K5F6Yc9cuDo

If, like mine, there is no through hole, you can grab the outside of the button and turn it while you add the spray.  I used a loose, 3-jaw chuck from a small lathe to grab the button heads.  The button heads are 0.780" OD and I think too large to grasp with any drill chuck.

The recess in the heads appears too small to allow fabrication of some expanding mandrel.  Even if you could make and fit one, I doubt it would hold much force for turning.

Be careful with the spray, it is toxic and can eat a lot of other things on your motorbike.  I would do it with the wheel off the bike and laying outdoors on some wood to keep the opposite disc off the ground.

Patrick Hayes
Fremont CA

[Sheepdog]

+1 on using spray brake cleaner. They run quieter, also.

[NewBoots]

Thank you Patrick. I will try that tomorrow and let you know if it works.
Bucky