Hello fellow TTrs. I'm all out of ideas and hope to tap into some experience from the TT community. This is a real brain melter to me...
Bike: 2011 YZ450f
Issue: Front brake dragging, slightly (the wheel will complete 3 or 4 revolutions with a firm spin) but enough to overheat the rotor after about 2 minutes of ride time
Details: I recently purchased a Galfer 270mm oversize rotor kit, (seen here: http://www.motosport...Brake-Rotor-Kit) with pads and relocation bracket. It's very important to know the brakes in stock form had absolutely no issue with dragging or heat. I have installed this same kit on my 04 and 06' YZ450f race bikes and am familiar with the process. After I installed the kit I could tell the brakes were dragging very aggressively, right away so I completely and thoroughly bled the brake system, with only a slight improvement. At this time, the wheel would spin maybe 1 1/2 to 2 revolutions with a firm spin. I then took out the new pads and re-installed the new stock pads that have 10+ hours and 80-90% padding. The problem improved, slightly.
Galfer: After a few calls to Galfer, they had me bevel the leading edge of the pads, re-bleed the system...none of this worked. So the kit was sent back to Galfer, everything was measure with micrometers and supposedly "in spec" and sent back to me. I would be suspicious of this claim, but Galfer (through MotoSport) had already refunded my money and were still willing to send the kit back to me, partially because it had signs of use and no longer could be sold as-new.
More interesting details: When I bolt the stock rotor back up with the pads, no issues...the wheel spins freely.
Also, if I don't torque down my axle, and leave the front wheel finger tight, lose, the wheel spins rather freely...it's only when I torque everything down that i get the dragging.
Thoughts/Observations: I have removed the pads and the rotor does appear to be near perfectly centered in the caliper pad holder (which is part of the Galfer kit), seems to me I can adjust this by letting my axle ride deeper into the fork by just a mm or two..which I tried and the problem didn't really improve.
I know it's not the caliper/master cylinder because the stock kit works great, i've literally re-installed the stock kit 3 times and test rode the bike and it's fine.
I have checked the new Galfer oversized rotor for warping by spinning the wheel on the axle without pads and it's 100% true, no vertical or horizontal wobble.
So, i'm completely out of options. I have never had to take my bike into a shop for repairs, i can do just about everything myself, but this is frankly embarrassing!
At this point i'm about to buy another Galfer oversized kit and if it bolts up without issue then i'll know it's them...
Frustrated, appreciate any helpful responses...