FZR 400 Front Brakes Severely Binding?

[Woddy]

Right then, installed the pistons this morning the OD was slighty smaller on the old pistons, they went in better, however they where binding just as bad when they where bled up :/. It seemed that the larger ones where not retracting like the smaller ones, so I split the calipers and cleaned thoroughly and I mean thoroughly behind the grooves (3 hours worth!) untill they where spotless, installed it all back and it is alot better spins 2 revolution now with a hard spin, but still grabbing slightly. My final call is going to be replacing the pad pins as they are warn (notched out) from the pad wear, also I noticed the M/C is leaking from the area where the lever touches the piston the brakes are still spoungy so I wonder wether the seals in the M/C have a part to play in that? I am hoping after doing the pins and M/C it should be good to go fingers crossed..

I Have searched high and low for pad retaining pins and M/C kit but found didly squat! Are the M/C rebuild kits the same as the FZR 1000'S & 600's etc?? Also are the front Sumimoto brakes the same as the FZR 1000's to, as this is the only pin I can find (link below) which is similar to mine;

http://www.ebay.co.uk/itm/YAMAHA-NOS-BR ... 4ab6d10b41

Sorry for dragging this topic on and on.. Almost there with it!!

Thanks

[Kurlon]

Might be worth hitting up Probolt to see if they've got suitable pins?

[Woddy]

I take back what I said sorry, just gone back into the shed and it spins 1 revolution not 2, just tried it with the banjos undone and still the same . I am all out of ideas now I have tried every trick in the book, there is no reason for this what so ever arghhhh!!! I even fitted new copper washers today and bleed nipples from Wemoto so the calipers couldnt be in any better shape!!

Kurlon thanks, I will send them a message I am gettin right down with it now

[Evilchicken0]

Could a disk have warped from the heat of the original calipers binding ????

[Woddy]

EC, I have tested the disks to see if they are warped but are perfectly straight, when you go to take the caliper off it is hugging the disk really tight. I have also tried the caliper on a VGC spare disk I have, so I still feel it's in the caliper - from what I can see the bigger pistons are still not returning and the smaller ones are returning slightly but are still not great! The only thing I can think of is the seals I put in not being genuine Yamaha seals!? Although the M/C seals seem shot I loosend the banjos and still the same, however does this method really 100% blank out the M/C being at fault??? As Taggy had the same problem with his brakes binding and that was due to the banjo being loose??

Thanks

[Evilchicken0]

Tbh I'm at a bit of a loss over these - whenever Yam brakes have been binding I've just cleaned them and they're fine, usually they'll go soft if there's a problem.

[Woddy]

EC it is very strange! I am trying a bit of everything today with them, just taken the disks of as the left side one was not sitting centre of the caliper and the rivets seem loose as they rattle when you put the disks down, I will try these other disks which are in alot better shape. I have to admit though they are alot better than when I first started out with them, I lifted the front end up on my old mans R1 (03 model) and that binds a little bit so I don't know if that is the nature of these things? I would like it to spin better than what it is doing though - 1 revolution carnt be normal!

I will plod on with it and see how I get on - I have done all that i possible could and I will do the M/C and get new pins, if it's no better then I will just run it for a bit and see how it goes!

Thanks to everyone that has helped!!

Any extra info would still be greatly appreciated !!

[Woddy]

EC, just a quik question - are the master cylinder rebuild kits the same on all the FZR'S & R6's etc as the FZR400? It looks exactly the same M/C as the one on my old mans R1 so I assume they are all the same internaly? Best to double check!

Thanks

[Evilchicken0]

I don't know for sure but I'd imagine it's only the ratio that changes

[Evilchicken0]

Could you borrow your old man;'s R1 and swap out the master cylinder onto your bike and/or put your calipers on his system to see if they bind.

You know if you put in new pads and everything it could be that they "just need to bed in" could you take the bike round the block a few times and see if they improve ????