another front brake question

I've cleaned and rebuilt my caliper. I have new pads, EBC from Chacal, and after putting them on the caliper it's too tight to fit the rotor.

I'm new at all this and not sure what to do at this point. I still have the old pads and they fit but I'd rather use new ones.

 

Did you push the piston back into the caliper?

 

Yes, as far as I could by hand.

 

is the piston all the way in the caliper? Should be pretty close to flush with the caliper. I use a c-clamp to push mine in when I replace pads, I just don't have the strength to push them all the way in with my fingers.

 

I'll try and push it with a clamp or something. I just wasn't sure if that was ok and thought I should check first

 

I used a clampto push in the piston and got a mm or two more clearance but it's still not enough.

So close and yet so far.

 

You might also need to remove some brake fluid from the Master cylinder to make room for what you're pushing back through the system.

 

The caliper is off the bike and not full of fluid.

 

If the system is drained the piston could be dry. try pouring in a small amount of brake fluid into the banjo bolt hole and lay it pad side down for a bit. It might lube the piston enough to allow it to slide better.

If that doesn't work then you will have to use compressed air or a grease gun to remove the piston, clean the caliper, and lube the piston with brake fluid and try again.

New pads will fit close to the rotor, but not so tight that you can't reassemble.

Be patient and methodical and you'll get it.

 

Did you thoroughly clean and polish the piston and cylinder....and clean the cylinder seal groove and use a new seal? It takes very little sludge to cause problems...and now is a good time to make sure all is right.......it will be a tight fit....but it will fit...

DaveC

 

You should have received a small sachet of red grease with the caliper rebuild kit. This is seal lubricant. If used when rebuilding brake systems it lubricates and preserves the rubber seals. If you haven't done this it's a snap to pop the piston, lube the seals and pop it back in. The grooves must be very very clean.

 

I pulled the piston back out this morning. Very easy this time, just some air pressure and it popped right out. I went back and lubed the caliper very well with clean brake fluid and it slid right into place. I think it was just a bit too dry.

Thanks folks!