Caliper Bolts WTF !!!
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Tourer
Joined: Apr 2009
Posts: 265
Likes: 0
From: Riverview, FL
Caliper Bolts WTF !!!
Just when I was happy with the break / rotor job on my 09 Ultra Classic, the damn caliper bolts came out.
I was on the way to work when I heard a "rattling" coming from the front end. I know that Harleys vibrate and shake, but they do not rattle.
I got off the bike and looked for what the problem could be when suddenly I discovered that one of the caliper bolts was missing and the other three were loose. So loose in fact that I could turn them with my hand. As I said before, I recently had new pads and rotors installed. I called the dealer, and he told me that they do not touch the rotor bolts on any of these jobs. I just can't buy that!!. How the hell did he install new pads without taking the calpter bolts off? If he installed new rotors, would'nt he need to manipulte the calipers, even if he did not take them off?
Dealer says to come by and they will "look" at the problem. I am pissed because this is definitely a safety issue!! 70% of the bike's stopping power is in the front brakes, and if the calipers are falling off, where is the stopping power? The bolts were so loose in fact that I could turn them with my fingers. Looks like the tech that did one or both of the jobs dropped the ball on this job. Aren't the bolts supposed to be torqued and LOCKTITE applied to keep them from backing out?
Am I FUBAR on this?
Dwayne
I was on the way to work when I heard a "rattling" coming from the front end. I know that Harleys vibrate and shake, but they do not rattle.
I got off the bike and looked for what the problem could be when suddenly I discovered that one of the caliper bolts was missing and the other three were loose. So loose in fact that I could turn them with my hand. As I said before, I recently had new pads and rotors installed. I called the dealer, and he told me that they do not touch the rotor bolts on any of these jobs. I just can't buy that!!. How the hell did he install new pads without taking the calpter bolts off? If he installed new rotors, would'nt he need to manipulte the calipers, even if he did not take them off?
Dealer says to come by and they will "look" at the problem. I am pissed because this is definitely a safety issue!! 70% of the bike's stopping power is in the front brakes, and if the calipers are falling off, where is the stopping power? The bolts were so loose in fact that I could turn them with my fingers. Looks like the tech that did one or both of the jobs dropped the ball on this job. Aren't the bolts supposed to be torqued and LOCKTITE applied to keep them from backing out?
Am I FUBAR on this?
Dwayne
Road Warrior
Joined: Apr 2008
Posts: 1,266
Likes: 7
From: Indianapolis
I think they're full of crap. I don't see how they could do pads and rotors without removing the calipers. It's probably one of those instances where they deny everything to begin with. I'm pretty confident they'll fix your problem. Once they do, find a different dealer because the tech there sure doesn't know what he's doing.
Road Master
Joined: May 2008
Posts: 803
Likes: 3
From: Collegeville, PA
I think the dealer is stone walling you. I have to unbolt the calipers to remove the front wheel on my FL. Otherwise the rim hangs up on the inner surface of the calipers. Can't see how he changed your rotors without removing the wheel and, therefore, unbolting the calipers. Ask him to show you how he got the wheel off to remove the calipers without loosening those bolts.
Seasoned HDF Member
Joined: Oct 2007
Posts: 8,852
Likes: 2,493
From: Decatur, Alabama
I would hope that any mechanic worth his salt would remove the calipers, clean and inspect them, and would also have to compress the wheel cylinder in order to be able to get the new pads in since they are so much thicker than the old ones. On my EVO bagger, cleaning the calipers and lubricating the pins is a regular scheduled maintenance item anyway. I can't imagine the newer ones being that much different. The torque spec for my caliper bolts is 30 ft/lbs. I'm not sure about using lock tite.
Just tighten up the bolts and go elsewhere for service. DON'T ride it with loose calipers.
Just tighten up the bolts and go elsewhere for service. DON'T ride it with loose calipers.
Grand HDF Member
Joined: Dec 2007
Posts: 4,999
Likes: 55
From: Bay Area
You have to remove the wheel to replace rotors, to remove wheel you have to remove calipers, to replace pads on frt calipers you can do it either way, at least on earlier years before abs that I know of.
The rotor bolts are not reusable, the book states that and new ones come with locktite patch on them, if you put chrome bolts you need to red l/t them. Did you use chrome mounting bolts ? HD does not sell chrome caliper mounting bolts, they have after market brand and the short lower bolt has no shoulder on it. I had them and my caliper was walking and pulled the threads out of my caliper. Your dealer just ****ed up and didnt torque them properly.
The rotor bolts are not reusable, the book states that and new ones come with locktite patch on them, if you put chrome bolts you need to red l/t them. Did you use chrome mounting bolts ? HD does not sell chrome caliper mounting bolts, they have after market brand and the short lower bolt has no shoulder on it. I had them and my caliper was walking and pulled the threads out of my caliper. Your dealer just ****ed up and didnt torque them properly.
Banned
Joined: Feb 2009
Posts: 6,259
Likes: 5
From: NW NC
I would like to see the magic wand someone uses to replace pads and rotors without removing the caliper. I'm calling billchit on this. Furthermore I would take it back and have the tech explain how this is accomplished and PLEASE let us know where he gets his wand at.
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Grand HDF Member
Joined: Dec 2007
Posts: 4,999
Likes: 55
From: Bay Area
You pry the pads back, loosen the pad pins, drop the inner pad and install new pad, replace pins, apply brake to seat pad against rotor, then pry back outer pad, remove pins, replace pad. etc. But I wouldnt do this on the front its a pita, much easier to remove calipers.
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Extreme HDF Member
Joined: Apr 2006
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From: Roswell, GA
d.a, per the 2009 HD Service Manual, the calipers are removed to remove the front wheel (which would need to be removed when changing brake rotors/discs). Also, per the SM, the caliper bolts don't get Loctitite.
The caliper bolts are listed as "critical fasteners" that are part of the routine maintenance at every scheduled service, so they should be checked for correct torque when scheduled maintenance is performed.
In short, the service dept. dropped the ball big time either at scheduled maintenance (if they did that for you) and/or when the new rotors were installed.
It would be nice if, as an owner, it wasn't necessary to know so much about our bikes (for example, knowing what service is required per the factory service manual) and we could rely on the dealer's service department to do what they are supposed to do. Unfortunately, relying on the service department to do what they are supposed to do often results in what you experienced.
Suggestion: spend the $50 or so and buy the HD Service Manual for your bike. Even if you don't do the work yourself, at least you'll know when the service manager or tech is ignorant or lying to you, and you may need to find a more reliable dealer for your bike.
Carl
PS: Contact HD's customer service and report what happened. There is a regional manager supervising dealer service departments who should be made aware of this situation.
The caliper bolts are listed as "critical fasteners" that are part of the routine maintenance at every scheduled service, so they should be checked for correct torque when scheduled maintenance is performed.
In short, the service dept. dropped the ball big time either at scheduled maintenance (if they did that for you) and/or when the new rotors were installed.
It would be nice if, as an owner, it wasn't necessary to know so much about our bikes (for example, knowing what service is required per the factory service manual) and we could rely on the dealer's service department to do what they are supposed to do. Unfortunately, relying on the service department to do what they are supposed to do often results in what you experienced.
Suggestion: spend the $50 or so and buy the HD Service Manual for your bike. Even if you don't do the work yourself, at least you'll know when the service manager or tech is ignorant or lying to you, and you may need to find a more reliable dealer for your bike.
Carl
PS: Contact HD's customer service and report what happened. There is a regional manager supervising dealer service departments who should be made aware of this situation.
