Rear Brake Caliper Woes

[DeePa]

I had to replace all 3 sets of brakes on my 89 suzuki quadsport 250s. The front ones were a breeze, but the rear ones are being a *****.

First, the piston doesnt feel like going back down into the caliper, so i pump the brake pedal, and this pushes the piston out of the hole, then I clean off all of the crud so it fits back in the caliper smoothly. (I know i need to bleed them after)

It gets pushed down all the way, and i install the 2 new pads and install the bolts ect. I go to put the caliper onto the disc, and it wont go on in one spot. On the bracket that connects the caliper and frame (or whatever, swiinger/ect) There is a little bump a few mm high, which is causing this to get all hung up. No matter what I do, I cant get the caliper onto the disc.

I tried installing the inner disc, then sliding the outer one in place, but that still will not work.

I am really at a loss at what to do except get a new caliper, rebuild mine, or get a refurbished one and send mine in for a core. Prices are 200 for a new one, 140 for a refurbished, and 80 for a rebuild kit.

What do you guys think? Is there a trick to this bullshit? How about my caliper options?

Thanks,
Mike

[lisnup65]

Pics would be helpful!