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Preynmantis 02-20-12 04:44 PM

Campagnolo Chorus caliper "rebuild" tutorial with pictures
Not sure if this actually qualifies as a "rebuild", but it was the best word I could come up with.

I am in the middle of my Canopus rebuild and I recently received the group that will get hung on the bike. As part of the group, I received a set of Campy calipers that needed some minor work. The more significant was the pads were well worn and hard, that and the calipers were a bit stiff and gritty in movement.

Being the adventurous soul I am, I decided to rebuild them while I wait on the frame.

The first picture shows the parts and caliper before use along with the tools I used (most of them). The LA's Totally Awesome cleaner is a wonderful degreaser for cleaning bike parts, it can be found at your local Dolllar Tree store.

The next picture shows removal of the brake pads since we will be replacing the inserts first.

The next shows the wear of the old pads vs. the new Kool Stop pads I picked up.

The first step to remove the old pad is insert a small screwdriver next to the pad and the holder...

... and twist. It starts to push out the pad.

You then continue to use leverage to keep puching it out. Some are really tight and others less so.

At the point that you have a bit exposed, you can grasp the pad with pliers and continue to pull it out.

A word of caution, these pads have a nut inside them that is just sitting there. Once it is exposed, it will just fall out.

To be continued...

Preynmantis 02-20-12 04:44 PM

Keep pulling the pad out until fully removed, repeat with the other side.

Use the degreaser to clean the holders. No sense putting it back together dirty.

The pads I bought did not have the notches cut in them to put in the retaining nut, so I had to cut them in. In this case, a good knife with a tanto point was important. Too bad Benchmade stopped making the Tanto Vex. I lined up the pads side by side and marked the new pads with lines where the notch would be cut.

Next I used a pair of dikes to cut the new pad along the lines down to the retaining groove.

I then used the knife to cut along the groove. This is where the tanto point helped out.

To be continued...

Preynmantis 02-20-12 04:46 PM

At this point, you should be able to just pop out the section.

Using the flat tip, clean out the bottom of the cut.

Checking for fit. I didn't make the cut wide enough... I had to widen a bit. I prefer this to trying to figure out how to put some back.

Now it fits flush. This is obviously necessary to prevent the pad from bulging out in the center.

Now we start to put the new pad in. Wet down the pad and holder since water is a good lubricant for rubber. You can start the pad without the retaining nut.

Once you get the pad in up to the notch for the nut, hold it in place and continue inserting the pad.

Once in, align the holes in the rear. A little judicious use of a rubber mallet helps a bit here.

The fruits of our labors.

To be continued...

Preynmantis 02-20-12 04:46 PM

Now on to the calipers.

Remove the cable retaining nut.

Using an awl, hold the retainer and remove the nut. This one was a 7mm. A word of caution here, I lay out the parts as I removed them so I can put them back in order. Do something that will let you know how to put it back together correctly.

Next we remove the center pivot nut. A 14mm cone wrench was useful here.

Spin off the nuts...

...and remove the center bearing washer.

Pop off the main spring...

...and remove the center assembly.

To be continued...

Preynmantis 02-20-12 04:47 PM

We now have a disassembled caliper. Clean parts with whatever suits you. Once the grime is removed, I tend to use steel wool to clean off light oxidation from the washers and other parts.

Using a small dab of grease...

...lightly coat the wear surfaces with a light coat of grease.

Position the washer on the caliper arms, the grease will hold them in place.

Use the awl to center the washers...

...and reinsert the main pivot assembly.

Reassemble in reverse order, putting grease on all wear surfaces.

Tighten everything down and admire your handiwork.

Bianchigirll 02-20-12 04:59 PM

After you done cleaning them send them my way Ok?

AZORCH 02-20-12 05:02 PM

Great thread!!!!

Preynmantis 02-20-12 05:02 PM

Originally Posted by Bianchigirll (Post 13876882)
After you done cleaning them send them my way Ok?

But then my Canopus might feel unloved. I am not sure I can risk that.

Originally Posted by AZORCH (Post 13876892)
Great thread!!!!


I stand in awe of the many tutorial threads I have found here to help me do the many things I have done. I thought I might add my humble part to the wealth that is C&V on Bike Forums.

buldogge 02-20-12 05:45 PM

Nice job...reminds me, I need to make some stainless conical nuts for a pair of Chorus brakes one of these days.

RobbieTunes 02-28-12 04:53 AM

Excellent tutorial.

Can't wait to see the "Magnum 'Opus"

That will be one killer bike.

Italuminium 02-28-12 11:58 AM

Nice work! Very kind of you to go through all the hoops of taking pics and writing a description.

gaucho777 02-28-12 12:10 PM

What, no video? ;) Thanks for the detailed pics and write-up!

Michael Angelo 02-28-12 06:42 PM

Nice work.

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