I am about to throw this quad under a bus!!!
   for some reason my front calipers don't line up anymore. i took them off and the hubs .cleaned them all checked the hub bearings (small amount of play) then put everything back together with new brake pads.Now they don't fit. looked over the clymer manual over and over again and just cannot see why this has happened.Could worn bearings and bearing dust caps be the issue?  has anyone had this problem or is it just me  not doing something correct .Should never of bought this friggin' thing as it is just sooo frustrating !!
 any ideas anyone?suzukiquadracerhq

  This Im afraid is your quadracer now  The difference between a novice and an attentive mechanical mind is worlds apart. goodluck< and let us know if you dont get it sorted.

Sounds like the hub bearing is not seated in all the way. an easy way to check that is to feel the bearing spacer and check if it seems sandwiched fully. I believe if you crank the spindle nut tight it should theoretically pull the bearings together squishing the spacer in tight and seat everything fully. correct?

Your factory calipers have two pionts that slide, side to side a bit. One is the piston. the second is the sliding bolts. The yfz450 calipers are the same technology/design but with dual pistons> not to be confused with opposing piston calipers wich have to work around different design and function. By the way those brakes your working with now are the identical design to 90% of the brakes on the road today.

ok
  badmoon, when you go to bolt on the caliper it hits the discs with the pad and will not line up.Its almost as if the hub is to far in .if that makes sense. i also cannot push the piston in any further.quick question ,should the piston and the rubber around the piston be flush to the caliper?
 Sublunacy ,thanks for pointing out im a novice, but i knew that already;). Checked hub bearings already and they are seated ok. I am not a complete novice as i worked on my other quad with no problems but with this one its just one thing after another and its just gets to you after a while .
Dezsled.  yes i have checked and lubed all those parts.

 tomorrows another day of trying !!!

Pretty much flush to the caliper.

pistons are flush to the rubber that surround the pistons,but the rubber is not flush to the caliper.the same on both sides.   but like i said they were the same both sides so i convinced myself this was how they should  be .
Badmoon you may have answered this already but not sure if you were talking about the pistons alone. Should the rubber around the piston be flush.?

 Thanks everyone and by the way i am not stupid (not really stupid anyway:) just getting incredibly frustrated with it and when that happens .........nothing is simple !!

Did you get the right pads?

Pics would help alot Andy -