200X Rear brakes question

[Frankencelery]

Several months ago I took apart the back brakes on my buddy's '85 200X (he stores it at my place...isn't that convenient) because they weren't working. I ended up rebuilding the caliper, but the pads weren't any good, so I threw them out. Just last week I finally got around to ordering new pads, and they don't seem to fit right. the backing plate is flat, and the portion of the caliper that holds the outer pad (right side) isn't flat. It is raised where the bolts go through. This makes the pad sit in the caliper at an angle. Do I have the wrong pads, or am I missing something?

I'd appreciate anyone who can help. Thanks in advance!

[Solid Snake]

It should sit flush against the caliper portion, the backside of the pads are definately flat, I just put new rear pads in my 200x rear caliper, which I also had rebuild (caliper piston was honed and new seals). When you get the new pads in tighten the bolts that go through them and then try to spread them apart to see if maybe you just aren't pressing them apart with enough force, there is a spring-like piece pushing against the pads that makes it tight to move the pads in the caliper. Lastly I'm not sure if this makes a difference but make sure you aren't missing that little bolt holder for the two bolts that go through the pads and the caliper to hold the pads, part number 23 in the diagram below,

http://houseofmotorcycles.bikebandit...me~ATC200X.asp

the reason I say that is because it also acts as a washer and will stop the bolts from possibly going in too far and having the threads push your outer pad in at the top. Hope this helps.

[Frankencelery]

Ok, so I think I've got the right pads. From the diagram that I saw, I am missing the "bolt holder", but that goes on the outside of the caliper and doesn't affect how the pads sit on the caliper. I'm still perplexed.

The "top" of the inside of the caliper, where the bolts go through, is raised about 1/8" over the rest of the C-shaped caliper holding surface. This puts the pad at an angle to the brake disc, which obviously isn't right. The inside or left pad fits fine. I still don't get it!

[Solid Snake]

I still think it will effect it because without it the two screw pins that go through the pads will go in farther then they should and the threads on the screws will go through the threaded portion and contact the pads at the top, see what I mean. Honestly I'm not sure if that is the problem but I would guess it is unless I could see your caliper itself, I'll go check my caliper tommorrow, I really don't think that the area there is raised at all, it should sit flush over the entire C-shaped area and the top portion. You may just have a lot of grime built up in there, try cleaning it out really good.

[Frankencelery]

The best thing I can do is show you with a picture. Have a look at it here:

http://kottum.mystarband.net/200XCaliper.jpg

See the raised area where the bolts go through? It looks to me like I've got the wrong pads. Is it possible that this is the wrong caliper? It fit just fine, with the parking brake and everything.

[Solid Snake]

I'm not going to be around my 200x for a long while, does someone mind checking this out on their 200x for frankencelery.

[Dirtcrasher]

Is there any possibility it was run for any time without the outboard pad and the rotor chewed the aluminum off of the caliper??

[Frankencelery]

No, it's not worn at all. In fact, I've seen calipers on Ebay that look like they may be the same way. I have to conclude that I'm missing an intermediate part that goes between the caliper and the brake pad, or I've got the wrong pads. As I said before, the backing of the brake pads are flat, and the caliper is not.

[Dirtcrasher]

Uhmm.. Yep, the ones on EBAY are junk also. If something inbetween the pads kept them straight then they could not close on the disc, your not missing any pieces or anything other than a good useable caliper. Here is a picture of a good 200X caliper.... That area is flat and the pad back surface is flat also.

[Dirtcrasher]

If you do find a stock caliper in good shape, there is actually an area at the lowest point of the brake backing area (ears) that was cast into it and is slightly raised, I'm not sure if you can see it in my picture as it's only about .010 thousandths or so. I too have a couple of these junk 200X calipers and what gets me is that the only way it can wear is that someone ran the trike with no outer pad.....