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[TheBoy]

Please read the guide, it has step by step instructions

At the point you are putting in pads, the top caliper bolt should be in place, and caliper hinged up. Place pads in caliper mounting bracket (not caliper), and hinge it down.

If it doesn't fit, either you have wrong parts, of piston not it.


//Assumption = front brakes. If rear, are you sure the disks are same as old - vented or solid?

[swordfish]

 front discs . sorry they are not new calipers . just new discs and pads. the piston is right back the pads are flush with the carriers . so should slot over the discs right well they wont .

[Elite Pete]

Push the bottom slider in where the bolt goes in to

[YZ250]

Are the discs and pads GM/TC/after market or otherwise. With the pads in place, the caliper should just swing down over them with a small amount of jiggling on the sliders.. Have you done simple maths and measured the disc thickness and pad thickness against standard.  I don't mean that rudely by the way.  Just trying to get a picture in my head of what's going on. 

[jonnyboyws6]

So is the width of the disc and pads bigger that the width of the caliper? If it is, and the piston is fully in, then there must be a problem with parts. If it isn't there must be something else stopping it going on... are the slide pins free throughout there full range of movement? If not they could be holding the caliper too far over to clear the outer pad? Can you actually see what is causing the obstruction?

Might be an idea to get someone else to have a look, you sound as if you understand the principles of how all this works, but best to play it safe when it comes to brakes.

[TheBoy]

Are the pads in the caliper or in the caliper mounting bracket.

Caliper pushed in fully.
Caliper bolted to caliper mounting bracket by its top bolt only, torqued to 30Nm, caliper rotated up as far as it will go.
Pads fitted to caliper mounting bracket.
Rotate caliper on its only fixing, over the pads.
Put in the 2nd caliper to caliper mounting bolt, torque to 30Nm.


If that doesn't work, you have a wrong part somewhere.

[feeutfo]

Can you confirm the caliper piston is retracted fully flush with the caliper?.... Or is it merely retracted/pushed back in as far as it will go? If the later then has the reservoir cap been removed to allow air and fluid to flow back up to the reservoir ? Because if the fluid is over filled for new pads and discs it will not allow the piston to retract fully. This may be causing your problem.
 Hence it's recommended to open the bleed nipple on the caliper to allow the excess fluid to escape "AS" the piston is pushed back then immediately nipped up to stop air getting in.

If piston is fully home in the caliper then can only presume wrong parts.

A pic perhaps?