Broke my V-Strom 250’s caliper bolt while changing the front brake pads
It snapped into two while I was tightening it down. Its bottom part got stuck in the caliper assembly.
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Prior to the Saturday ride in July, I had checked the brake pad thickness and it looked more than 1mm without taking out the calipers. During the 200 odd kms ride, I didn’t notice anything wrong with the front brakes. Just as I was getting back into the apartment parking lot, I could hear screeching front brakes. I quickly checked and the pads were thinner than the previous day. I parked the bike and later in the day took out TVS Jupiter to head to the Suzuki service center to buy front brake pads. Got the set (Part no. 59140-34810-000) for Rs. 584, manufactured in Mar ’23.
On Sunday noon, decided to only check the brake pad thickness to decide if it could be ridden to the service center or not. In the morning, had checked out Ari Henning’s video on brake pad change with no intention of changing pads on the same day.
Went down to the parking with most tools, 1/2″ socket set, and new brake pads. Removed both axial bolts and this was the sight. It had gone beyond the limits, and should have replaced the brake pads even before the Sat ride.
Removed both pins to take out old pads, here is a comparison of old with new. Pads thickness 0.9mm Vs 4.7mm.
At this point, I felt let’s change brake pads, no need to visit the service center.
Next task was to push back pistons to make room for new pads. I started pushing piston one after the other only to reach the situation of one in, the other out.
That made me realise Ari’s mention of opening the brake fluid reservoir, had forgotten about it. Spread a rag for any unintentional brake fluid spill and went back to pushing back pistons.
New brake pads in place
Fixed brake fluid reservoir cap and last thing was to tighten axial bolts. Almost the entire DIY went well so far. Just as I was tightening 2nd bolt with a ratchet handle, more torque got applied (perils of not carrying a torque wrench) and the bolt snapped into two.
Next task was to remove the bottom part of the broken bolt.
Plenty of thoughts cropped up in my mind as I was picking up things in parking. What if:
- I would have stuck to the initial part of the DIY
- I would have used a small ratchet handle
- I would have used a torque wrench for the correct torque (26Nm)
I couldn’t spare time in the upcoming week to delve much other than trying to remove the bolt with different pliers. I decided to visit auto workshops in the suburbs. First I visited a welder and his suggestion was to get the braking system removed from a mechanic and then explore removing the bolt. Found a mechanic working on an RX100 two outlets away. Mechanic’s idea was to remove the front wheel and slide out the brake system from the brake disc.
He put up a jack with a wooden block beneath the engine to lift up the front wheel and then the search started for the 12 mm Allen key. He didn’t have it, he checked with nearby 4-5 workshops that also didn’t have it.
The next thing was to use a 12mm bolt with a longer handle welded to it. Unfortunately, that didn’t work either. Myself and mechanic decided to visit hardware shops in the suburb to get a 12mm Allen key. I tried at New Rekha Hardware, but his stock was over and promised to get it the next day. I picked up bolts from there, it was a black, unfinished one.
Luckily, the mechanic got it from another hardware store and we could proceed with removing the front wheel. Next things were easy, we were able to get enough space to remove the bolt with a plier, no need to go back to Welder.
Mechanic asked for Rs. 30 for his work. I wanted to pay and get the Allen key but he said he would need it for other work.
Cost of DIY blunder wasn’t much, however, the anxiety it caused was priceless.
In the end, few learnings
- Check brake pad thickness often
- Carry ATTATT(All the tools all the time) just like ATGATT(All the gear all the time)
- Stick with DIY plan(even if it’s in parts)
Check out BHPian comments for more insights and information.
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