Topic: rebuilt brake caliper sticks - HELP?

[pelicanwheel]

Hi gang -

I just installed my new rebuilt front system and am stumped.  The first problem is that the new EBC brake pads both had to be pressed into each half of the caliper.  I did this with my bench vise.  The fit was just that tight.  I assumed the fixed pad wasn't going to be a problem with having been pressed in.  I'm worried about the the piston side pad, though.  The caliper was powder coated down 1/2"into the pad pocket (just above the rubber seal.  When the pad would not go in, I assumed that it was suppose to be that tight.  but after tapping it with a rubber mallet a couple times, I though that maybe the paint took to much space.  I took a dremel tool with a brass wire wheel and cleared the paint.  The pad still fit tight.  At this point, I assumed that it was suppose to be that way, being new and all.  I went ahead and pressed the pad in with the vise.  It was really really tight going in.

When I mounted the wheel, I installed dot 5 fluid, bleed and the lever feels relative firm.  The problem is that the wheel is not stuck because the pads will not release, having been pushed out as a result of bleeding the system.

Questions to the board:

Are the pads supposed to be that damn tight?  I assumed this because they sure as hell were that tight when I disassemble the calipers.

IF they are to be that tight, how in the hell do you move the bike with the brakes locked?


Could I possible have the wrong pads?

Do I need to pop the pads back out (oh joy!) and perhaps file them to be smaller in diameter?

Welcome all comments.

Pelican

[pelicanwheel]

I meant to say the brakes are NOW stuck.

[Kevin400F]

The pad on the piston side should be an easy "slip fit" in the caliper bore.  You'll need to pop it back out and resolve the clearance problem.  Make sure the caliper bore is perfectly clean of any paint/powder coat.   Chances are the EBC puck is simply too large.  I put a vernier caliper on several old pads here in the shop and they measure 2.045"-2.050".   Your old pad was tight due to corrosion build-up, and the new clean puck should have a few thousanths clearance. 

[sparty]

The pads are not supposed to be that tight, you have the wrong size pads in there bro.  That is why your pads won't retract.

I rebuilt my caliper a few months ago.  I bead blasted it and had it powder coated, but my pads are not tight at all.  My caliper is a 1972 CB750 caliper with EBC pads  I am thinking that you have the wrong pads, my pads have about 1/8 to 1/4 inch of clearance all around. 

Sparty

[pelicanwheel]

damn...I was afraid that was the problem.  Did they make ever so slightly different pad sizes for the different years?   Jeez!

[750goes]

mate if you had to push them in with the aid of a rubber mallet - bells should have been ringing then - even with the powdercoating..
the fixed side shoud just slip in out, being retained with the small split pin. the piston side should do the same..

pump the piston out, and get the right pads as the current ones won't work..
did you compare the new pads to the old ??

[crazypj]

I've had this problem a couple of times with EBC pads. They are painted on edges and there can be a 'lip' of paint/bonding agent
I usually take a small file and remove any burrs/paint build up so it slips easily into caliper.
PJ