Troubleshooting Campagnolo Ekar AFS Disc Rotors: How to Fix Common Braking Issues

The Campagnolo Ekar AFS Disc Rotors [paid link] are high-performance components designed for road bikes that are built to provide excellent braking performance under various conditions. However, like all bike components, they can encounter issues that affect their function. Understanding how to troubleshoot and fix common braking problems with these rotors will ensure optimal performance and safety. In this guide, we’ll discuss the most common problems cyclists may face with the Ekar AFS Disc Rotors [paid link], their causes, and how to fix them.

1. Squealing or Noisy Brakes

One of the most common issues cyclists face with disc brakes, including the Campagnolo Ekar AFS Disc Rotors [paid link], is squealing or noisy braking. This can be particularly frustrating, as it impacts the overall riding experience.

Causes of Squealing Brakes:

Contaminated Rotors or Pads: Dirt, oil, or brake fluid on the rotor surface can cause squealing. Even a small amount of contamination can significantly reduce braking performance and create noise.
Improper Pad Bedding-In: New brake pads may squeal if they are not properly bedded in, as they have not yet established a smooth surface that matches the rotor.
Rotor Misalignment: If the rotor is not properly aligned with the brake pads, it can cause uneven contact and lead to noise.
Worn Brake Pads: As pads wear down, they may no longer make consistent contact with the rotor, causing noise.

How to Fix Squealing Brakes:

Clean the Rotor and Pads: Use a brake cleaner or isopropyl alcohol to thoroughly clean the rotor and pads. Make sure to remove any contaminants that may have built up.
Bedding-In the Brake Pads: If your pads are new, ensure that you properly bed them in. Perform a few braking cycles at moderate speeds to establish a consistent surface.
Check Rotor Alignment: Ensure the rotor is correctly aligned with the brake pads. If necessary, adjust the caliper to ensure the pads are making even contact across the full surface of the rotor.
Replace Worn Pads: If the pads are worn down, replace them with new ones to restore proper braking performance and reduce noise.

2. Brake Pad Wear and Rotor Grooves

Another issue with the Ekar AFS Disc Rotors can be excessive pad wear or the formation of grooves in the rotor. Grooves on the rotor surface can lead to inconsistent braking and might damage the brake pads, leading to reduced performance.

Causes of Excessive Pad Wear and Rotor Grooves:

Hard Riding Conditions: Frequent hard braking or riding in challenging conditions like wet or muddy terrain can cause the rotor to wear down faster and create grooves.
Incorrect Pad Material: Using pads that are not compatible with the rotor material or not suited for the riding conditions can lead to increased wear.
Improper Brake Pad Alignment: If the brake pads are not properly aligned with the rotor, they can cause uneven wear and groove formation on the rotor.

How to Fix Excessive Pad Wear and Rotor Grooves:

Inspect and Replace Brake Pads: Check the brake pads regularly for wear. If they are worn beyond the recommended limit, replace them. Ensure that you use the correct pad material suited for your riding conditions.
Resurface the Rotor: If your rotor has deep grooves, it might need resurfacing. Some rotors can be machined to remove small imperfections, but if the grooves are too deep, a full replacement may be necessary.
Ensure Proper Pad Alignment: Make sure that the brake pads are correctly aligned with the rotor. Misalignment can lead to uneven wear, damaging both the pads and the rotor.

3. Reduced Braking Power or Spongy Feel

A spongy brake feel or reduced braking power is another issue that riders may encounter with the Campagnolo Ekar AFS Disc Rotors. This can make it difficult to achieve the stopping power required, which is especially critical for road safety.

Causes of Reduced Braking Power:

Air in the Brake Lines: If you’re using hydraulic brakes, air bubbles in the brake lines can create a spongy feel when you press the brake lever.
Contaminated Brake Fluid: Contaminated brake fluid can also lead to reduced braking performance by affecting the hydraulic system’s ability to transfer pressure properly.
Incorrect Pad-Disc Contact: If the rotor and brake pads are not making full, even contact, it can result in reduced braking power.
Worn or Damaged Rotors: Over time, rotors can become warped or damaged, leading to uneven braking surfaces and less effective stopping power.

How to Fix Reduced Braking Power:

Bleed the Brakes: If you’re using hydraulic disc brakes, a simple brake bleed can remove air from the brake lines, restoring the proper braking feel. This process involves using a special tool to replace the air with brake fluid.
Replace Contaminated Brake Fluid: Flush the old brake fluid and replace it with fresh fluid to ensure consistent braking performance.
Check for Pad-Rotor Contact: Ensure that the pads are correctly aligned with the rotor, and that there is even contact across the surface. Adjust the calipers if necessary.
Replace Worn or Damaged Rotors: If the rotors are severely damaged or warped, they may need to be replaced to restore full braking power.

4. Rotor Warping

Rotor warping is a serious issue that can negatively affect braking performance. Warped rotors can cause uneven pad contact, leading to inconsistent braking and vibrations during braking.

Causes of Rotor Warping:

Overheating: Prolonged or excessive braking can cause the rotors to overheat and warp. This is especially common in long descents or when riders frequently apply the brakes.
Improper Mounting: If the rotor is not installed correctly or is torqued unevenly, it can lead to warping.
Impact Damage: Dropping the bike or hitting the rotor with a foreign object can cause physical damage, resulting in warping.

How to Fix Rotor Warping:

Check Rotor Mounting: Ensure that the rotor is mounted correctly and securely to the wheel hub. The mounting bolts should be evenly tightened to the recommended torque specifications.
Replace the Rotor: If the rotor is significantly warped, it will need to be replaced. A warped rotor can’t be effectively straightened and may cause damage to the brake pads.
Monitor Braking Temperatures: Avoid overheating the rotors by applying consistent, controlled braking. Consider installing a rotor with better heat dissipation if you frequently ride in challenging conditions.

5. Inconsistent Brake Feel Between Front and Rear

Another issue riders may encounter is inconsistent brake feel between the front and rear brakes. If one brake feels stronger or weaker than the other, it can affect the overall braking performance and balance.

Causes of Inconsistent Brake Feel:

Uneven Pad Wear: If the brake pads on one rotor are more worn than the other, it can cause an imbalance in braking power.
Caliper Misalignment: If the calipers are not correctly aligned, one brake may be applying more force than the other.
Fluid Imbalance: Hydraulic brake systems can experience fluid imbalances if there is a leak or improper fluid levels in the brake lines.

How to Fix Inconsistent Brake Feel:

Inspect Pad Wear: Check the brake pads for even wear. Replace any pads that are excessively worn, and ensure both pads are making consistent contact with the rotors.
Align the Calipers: Ensure that the brake calipers are properly aligned with the rotors. Misalignment can result in uneven braking and poor performance.
Check Fluid Levels and Bleed the Brakes: If you’re using hydraulic brakes, check the fluid levels and perform a brake bleed to eliminate any air bubbles or fluid imbalance.

By addressing these common issues, you can keep your Campagnolo Ekar AFS Disc Rotors performing at their best. Regular maintenance, proper installation, and troubleshooting these problems as they arise will ensure that your bike delivers reliable braking performance, whether you’re riding on the road or tackling more technical terrain.