Join Date: Oct 2008
Location: Springfield, MO
Thanked 253 Times in 216 Posts
Well ...... It was a classic case of supreme dumbassery on my part. Even after laying everything out in order, I somehow managed to swap the inner caliper halves - RH inner got bolted to LH outer, LH inner got bolted to RH outer. It was immediately evident as soon as I broke them apart. The two inner halves are identical except for the fluid passage hole, so maybe I got distracted during the critical moment of mating the parts, lol. It's all back together and bled. I'm chasing the elusive rock-solid lever, so for now I have the lever tied back against the throttle tube.
Just for any future reference - it is impossible for the piston to be all the way into the caliper, there is a small protrusion at the bottom of the caliper bore that holds it out far enough for fluid to get behind it.