i have bought rear pads for my 1999 400 ex from the dealer they are to tight to fit over the rotor when installed. what adjustments can i make to get the new pads to fit? i have released the brake fluid, are there adjustments on the caliper? the old pads were almost to the metal, would that make a difference?

 

hmm i've never done brakes on a quad, but i've done them on cars so i take it its basically the same. when u say u release the brake fluid, do u mean u pushed the caliper piston back in to the caliper? if u didnt im guessing thats ur problem.

 

the caliper is fully compressed. but the pads still won't do over the rotor.

 

i just out new pads on my 00 400ex and all i did was take out the ald ones, wich also were bare metal, squeezed the piston bak inside the caliper with cannel locks and the new pads went on and slipped rite into place.

are you sure that they are the right pads and the piston is all the way in?

 

Very important to clean off the pistons with brake cleaner and tooth brush. Also before pushing pistons in be sure the reservoir brake fluid level is near the low level. Then just push the pistons in with either your fingers, or with old pads covering piston and vice grips.
If you don't clean pistons before pushing them into calipers there is very good chance that caliper seals will start leaking.

 

the pads are the correct ones, checked twice with 2 different dealers.

the piston is fully compressed. how thick should the rotor be?
is there any possibility there are after market calipers, that require different pads?
what was your pad #'s for the 2000 400 ex?
thanks guys

 

try cracking the hydraulic line before trying to depress caliper...if it works and system feels spongy...bleed all 3...and like old turtle said....extend the caliper...clean....then depress...how this helps