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Shortly before last ride of 2010 I had my tires changed from street type to Karoos (front & rear). Braking up to that point had been fine.

On first ride with Karoos I immediately noticed rear brakes seemed extremely weak. I was literally standing up on rear brake lever with barely any stopping power. Lever also seemed to depress way further down than before. Friend changing tires thought due to ABS and knobby combo, limited contact patch, ABS was constantly kicking in way too early, or always on, and slow stopping was result.

As I never noticed such an extreme change up front, albeit with 2 discs not one, I don't think it is due to ABS.

Later, brake pad insulators got mangled somehow after friend took the rear tire off/on again to check why so weak. We noticed they got mangled so I did not ride with them so no indirect brake damage could have resulted.

Later while on centerstand I noticed rear brake grabbing. Whether related to weak braking within a few miles or somehow just coincidence with the weak brakes I don't know. I remember weak brakes, but not binding on first ride with new tires, though I wouldn’t have necessarily noticed or been looking for binding with a short ride around the block.

That night mangled insulators were straightened as best they could and reinstalled. I didn't ride much after that as was already late in season. However it happened, due to knowing about rear brake weakness/grabbing, I tended not to use the rear brakes at all so don't know if the weak brake issue continued, changed to the grabbing, or is currently still there or not? (Bike still in the shop).

Although still unsure about weak brakes, right now rear brakes are binding, not enough to not be able to move, but enough that after riding without even using the rear brake the rear disc is extremely hot. Also when bike is on centre stand and try spinning wheel will barley complete one rotation.

New mechanic says he's tried everything. The wheel is square to the chain and swingarm, wheel spins freely when brake pads are off. Nothing is bent. Although original brake pads were fine they were replaced. He has installed new EBC brake pads (without the 2 Insulators (backordered)). He has also bled brake lines, added correct amount of new fluid, and checked the alignment of the pads, checked the caliper and cannot find anything anywhere that is making it stick. Disc is not bent.

Any ideas???
 

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FORUM GODFATHER.....R.I.P. PAT
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There are only two places sticking can occur, the piston itself and the slider pins. If the piston was cocked in the bore, the bore would be damaged and the caliper would need to be replaced. The slider pins #5, #7 and an outside chance on #9 are more likely to be damaged. They could be bent or just may need to be cleaned and lubricated with silicone based brake grease. See if you can push the piston into the caliper. If that can be done, check the sliding action. With the piston pushed in the caliper should be able to move side to side freely between contact with the rotor on each side. Check the pins for straightness and lube.

 
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