The Most Common Campagnolo Ekar AFS Disc Rotor Problems and How to Solve Them

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The Campagnolo Ekar AFS Disc Rotors [paid link] are a reliable and high-performance braking component for gravel and road bikes. However, like any mechanical component, they can experience issues over time. Understanding the most common problems with these rotors and how to fix them will ensure your bike’s braking system stays at its best performance. In this guide, we’ll explore the typical problems riders face with the Campagnolo Ekar AFS Disc Rotors [paid link] and provide you with effective solutions.

1. Rotor Warping or Uneven Wear

Problem:
One of the most common issues with the Campagnolo Ekar AFS Disc Rotors [paid link] is warping or uneven wear, which can lead to braking inconsistencies. Warping occurs when the rotor is exposed to extreme heat, such as from excessive braking or riding conditions that cause the rotor to heat up. This leads to the rotor’s shape becoming distorted, which causes it to rub against the brake pads and results in a pulsing or uneven braking feel.

Solution:

  • Check for Warping: Place the rotor on a flat surface, and use a rotor truing tool to assess if it is out of true. Spin the wheel while visually inspecting the rotor to spot any visible wobble.
  • True the Rotor: If the rotor is slightly warped, use a rotor truing tool to gently straighten it. Apply light pressure to the edges of the rotor, working from the center outward, to bring it back into alignment.
  • Replace if Necessary: If the warping is too severe, or if truing doesn’t resolve the issue, it’s best to replace the rotor to maintain optimal braking performance.

2. Noisy Braking (Squealing)

Problem:
Another common issue with the Campagnolo Ekar AFS Disc Rotors is noisy braking, particularly a high-pitched squeal or grinding noise. This can be caused by various factors, such as contamination on the rotor, improperly bedded brake pads, or misalignment of the brake pads.

Solution:

  • Clean the Rotor: Use a rotor cleaner or isopropyl alcohol to clean the rotor thoroughly. Dirt, oil, or grime on the rotor surface can cause the pads to slip, leading to squealing.
  • Check Brake Pad Alignment: Ensure that the brake pads are properly aligned with the rotor and are making even contact with the braking surface. Misaligned pads can cause uneven wear and squealing.
  • Bed-In Your Brake Pads: If you have recently replaced the brake pads, make sure to follow the proper bedding-in procedure. This process involves a series of gradual stops from varying speeds to ensure even pad contact with the rotor and to minimize noise.
  • Check Pad and Rotor Condition: If the squealing persists, check the condition of both the rotor and brake pads. Worn pads or a grooved rotor surface may require replacement to eliminate the noise.

3. Brake Pad Rubbing or Drag

Problem:
Brake pad rubbing or drag occurs when the brake pads make constant contact with the rotor even when the brake lever is not engaged. This can lead to reduced braking performance and increased wear on both the rotor and pads.

Solution:

  • Check Pad and Rotor Alignment: Ensure that the brake caliper is aligned correctly. If the caliper is off-center, the pads may be misaligned with the rotor, causing rubbing. Use an Allen wrench [paid link] to adjust the caliper position so the pads are parallel to the rotor surface.
  • Check for Rotor Contamination: Contamination on the rotor surface can cause brake pads to drag. Clean the rotor with isopropyl alcohol to remove any dirt or oil.
  • Inspect Pad Wear: If the brake pads are unevenly worn or have become glazed, replace them to eliminate rubbing and restore optimal braking performance.

4. Reduced Braking Performance

Problem:
If your Campagnolo Ekar AFS Disc Rotors are showing reduced braking performance, it could be due to several factors, including worn-out rotors, pad contamination, or air in the hydraulic brake lines.

Solution:

  • Check Rotor Thickness: Over time, disc rotors wear down, losing their effectiveness. Measure the thickness of the rotor using a caliper. If the rotor thickness is below the minimum recommended by the manufacturer (typically 1.5mm), it should be replaced.
  • Inspect and Replace Brake Pads: If the pads are excessively worn, they can cause reduced braking power. Check the thickness of the brake pads and replace them if they are near the wear indicators.
  • Bleed the Brakes: Air bubbles in the hydraulic brake lines can cause a spongy feeling and reduce braking efficiency. Bleed the brakes to remove air from the system and restore proper braking power.

5. Rotor Debris and Dirt Buildup

Problem:
Debris such as dirt, sand, or gravel can accumulate on the rotor and cause a reduction in braking power, uneven wear, or noise. This is particularly common when riding in off-road conditions.

Solution:

  • Clean the Rotor Regularly: Regular cleaning is essential, especially after riding in dirty or wet conditions. Use a soft cloth or dedicated rotor cleaning brush to remove any buildup of dirt or grime.
  • Use a Brake Pad with Better Contamination Resistance: If you frequently ride in muddy or wet conditions, consider using brake pads designed to resist contamination and prevent excessive buildup on the rotor surface.

6. Rotor Mounting Issues

Problem:
Incorrectly mounted rotors can cause uneven braking, noise, or poor performance. A loose rotor or improperly torqued rotor bolts can also lead to unsafe riding conditions.

Solution:

  • Ensure Proper Mounting: Check that the rotor is securely mounted to the hub. The mounting bolts should be tightened to the correct torque specification to prevent any movement. Use a torque wrench [paid link] to ensure the bolts are tightened to the recommended specification (usually around 6Nm).
  • Inspect the Rotor for Damage: Look for any cracks or significant dents that could compromise the rotor’s integrity. If the rotor is damaged, it should be replaced to ensure your safety.

Conclusion

The Campagnolo Ekar AFS Disc Rotors are designed to offer superior braking performance on gravel and road bikes. However, like any high-performance component, they may experience issues over time. By understanding the most common problems, such as rotor warping, noisy braking, pad rubbing, and reduced performance, you can take the necessary steps to troubleshoot and resolve these issues. Regular maintenance, proper installation, and timely replacements will ensure that your braking system remains in peak condition for the long haul.