brakes binding :(

[damz]

just finished fixing up my zx7r and while removing the rear wheel the brake disc broke (was a fugly flimsy wavery disc) and so i bought a new one. however it is much thicker than the old one and when i fitted the caliper and pads onto the disc it is now binding badly. usually what i would do is take the pads out and press the brakes to get the pistons out then split the caliper and take the pistons out and clean tem.

however on these tokico (sp) calipers i need to split them before i can take the pads out as the retaining pins are built into the caliper.

only way i can think of sorting it out is to split it, take out the pads, put it back together, bleed it the brakes, pop the pistons out and then do it all over again after putting the pads in.

is there an easier way?
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Current Bikes RVF400 - 94
Cars: RX7 FD, Eunos Roadster
Former Bikes: FZR 250R 89, ZX7R 98

[alun111]

I'm sorry but I just don't believe that kawasaki would use a caliper that had to be split to change the pads
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Summer: '00 Honda CB600F Hornet
Winter: '93 Suzuki GSF 400 Bandit VP Variable Valve
Past Bikes: Lifan LF100-5 Lifan LF125-A Honda C70

[Itchy]

Nope, you should have cleaned them before you pushed the pistons in, the fact that they are binding means that the dirt has already passed and or gotten round the seals.

There is one last thing you can try and that is to pump the piston out as far as you can, then clean it up push it back in then clean it up again to try get the dirt out, but sooner or later you are going to have to pop the piston out completely and clean the seals up.
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Spain 2008France 2007Big one 2009 We all die. The goal isn't to live forever, the goal is to create something that will. In the end, your life will flash before your eyes. Make sure it is worth watching.

[TUG]

Sounds like you need to strip them anyway, its a 5 min job then 10 to clean.
I need to do a write up on this and a few other things aswell and have them stickied.
Pump the pistons out with the pads still in as you cant remove them anyway.
Remove from bike and place in big heafty vice and swing away.
Now... removing the pistons, this is where you damage them and theres nothing you can do unless you own a caliper piston clamp (sealy make one) i just use pliers.
Remove and clean, now it might be worth removing the dust seal and cleaning its groove aswell as you might be suffering from seat corrosion.
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Haz ER-5, innit!