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Front Brake Disc Swap Problem

Discussion in 'The Garage' started by Hasty, Sep 21, 2022 at 11:22 AM.

  1. Hasty

    Hasty 1982 Maxim XS400

    My engine finally runs great thanks to the forum, but when I took the bike to get safetied, they told me my front rotor is too warped to pass. I haven't had any problems with it so it's a bit annoying, but can't fault the mechanic for being thorough I guess. Getting it replaced is now a time sensitive thing though because I don't want to have to pay for a second safety.

    So I happened to find a disc for sale in town from an XS650 that is the right diameter, right bolt holes, right offset, it's just a little thicker than my old disc. I collapsed the cylinder in a bit and everything fits fine with my current brake pads which have a fair bit of life left in them, BUT if I put in new pads, the inside pad (the side that is stationary and isn't actuated by the cylinder) sticks out too far and I can't get the disc in. Any ideas out there for how I can get the new pads installed? Is it totally insane to just grind down a fresh brake pad about halfway so it fits? Do I just need to get wider calipers or a thinner disc?

    Photos attached of the current partially worn pads with the new disc so you can see what kind of clearance I'm working with

    Attached Files:

    Last edited: Sep 21, 2022 at 11:32 AM

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