Originally Posted by enjenjo
Take the front tires off, and put a wedge of some kind behind the outer pad so the piston is forced in all the way. Then try your pedal. I have had new calipers that the seals pull the piston back far enough to cause this problem, paticularly with turned rotors. A 2 lb residual valve in the front brake line usually cures it, and causes no ill effects.
Try this. Really. It is a common problem.