I had to replace all 3 sets of brakes on my 89 suzuki quadsport 250s. The front ones were a breeze, but the rear ones are being a *****.

First, the piston doesnt feel like going back down into the caliper, so i pump the brake pedal, and this pushes the piston out of the hole, then I clean off all of the crud so it fits back in the caliper smoothly. (I know i need to bleed them after)

It gets pushed down all the way, and i install the 2 new pads and install the bolts ect. I go to put the caliper onto the disc, and it wont go on in one spot. On the bracket that connects the caliper and frame (or whatever, swiinger/ect) There is a little bump a few mm high, which is causing this to get all hung up. No matter what I do, I cant get the caliper onto the disc.

I tried installing the inner disc, then sliding the outer one in place, but that still will not work.

I am really at a loss at what to do except get a new caliper, rebuild mine, or get a refurbished one and send mine in for a core. Prices are 200 for a new one, 140 for a refurbished, and 80 for a rebuild kit.

What do you guys think? Is there a trick to this caliper install? How about my caliper options?

Thanks,
Mike

 

I've had to grind down the pads to get calipers on with new pads, it can be your only choice when thiers not enough gap in the pads for the disk.