Okay, so I ordered a new set of EBC rotors and pads from Murph. Went about R&R. No issues during install. Everything went on clean and exactly as before.
I went to seat the pads. I started off slow and made some light, initial brake applications. As I increased speed, I could feel a shudder, maybe even worse than a shudder. It's as if there's a fracture in one of the rotors that's catching the edge of the pad as it rotates through. I pulled over and looked over the front end and can't find anything wrong. Not finding anything unusual, I proceeded to continue more brake applications. The more I tried to seat the pads, the worse the shudder got. It's almost like a "clunk clunk clunk" as the wheel makes each rotation.
I double and triple checked all of the bolts for the calipers, the axle, the pinch bolts, fender bolts. I put the wheel on in the correct direction and the ABS ring on the correct side. When I bolted the new rotors, I snugged them in a star pattern like a wheel on a car. I used the original gaskets that were between the original rotors and wheel hub. The spacers for the axle are correctly in place. The pads are lined up properly with the pins and springs. I placed the rotors with the EBC labels visible on both sides.
When I spin the front wheel while on the center stand, the pads ARE rubbing a bit. The wheel doesn't spin very freely. I suspect that my calipers could use a rebuild, but I can't see how that would cause the clunking sound. The rotors seem true, not bent in any obvious way.
Did I miss something?
Any advice or help would be greatly appreciated.
Ray
UPDATE. So, while continuing to work on this, I wanted to test for warping. I put a zip tie around the front lever and the grip to maintain a constant pressure. As I rotate the wheel, there is strong resistance until I get to one spot and the wheel turns much easier. It would seem as either the rotor is warped or there's grease on it (which there isn't, I cleaned the rotors before and after install).
What should I do from here?
FINAL UPDATE: I contacted Murph through their website last Friday explaining the problem and the troubleshooting. Oscar contacted me over the weekend and said he’d contact his EBC guy and let me know on Monday. On Monday, Murph emailed me to let me know EBC was sending me a replacement directly. Today, Wednesday, the rotor came in. I replaced the defective one and now all stops are nice and smooth!