Sorry for all the following questions, but it will help to troubleshoot source of the problem:
Question 1) Are the brake pads stock HD (somewhat soft friction material) or "high performance" (semi-metallic aftermarket somewhat harder friction material)? Also, do the pads have slot in the friction material to allow debris and water to clear the swept area?
Question 2) The new rotor(s), are they stock HD or high performance rotors and did you do the same using sanding block w/ wet/dry sandpaper in circular motions to put a random satin finish on the swept surfaces, then clean off any contaminates using water or Brakleen over rags?
Question 3) Did you roughen the friction surface of the new pads with sanding block w/ wet/dry sandpaper in circular motions to remove manufacturing marks/sprue then clean off any contaminates using water or Brakleen over rags?
Question 4) Are the sheet metal shims that clipped firmly to the pad clean and contact the piston as before...Did they have any evidence of "old Blue stuff" (per previous post regarding HD Service Bulletin "Noise Fix" as evidence of HD previous troubleshooting, so clean old off and put new stuff on). Thermal/performance apparently is not an issue in this application
Question 5) Did you remember to check pins for wear/grooving/fit and lube the pins and the calipers "float freely, fit snuggly and slide evenly without "wobble" over the rotor swept surfaces.
Question 6) Do you see evidence of "stutter" type wear pattern on the rotors, as if the pads were engaging improperly instead of flat and even circular wear pattern on them?
Question 7) Is the squeal a low pitched vibration when the bike is moving slowly, and only high pitched when deaccelerating from high speed and can you hear the squeal just pushing the bike rather than a light "swish" sound?
Question 8) If all above was done, during your 100 mile breakin did you use regular firm braking, with periods allowing pads to separate and cool? Make sure that you did not overheat them, as the pad surfaces can get "glazed" (basically hard carbon burned surface) if used during say a long downhill braking sequence. You will see evidence on the pads when you inspect them prior to repeating the steps 1-4...while you are troubleshooting...:coffee
If all the steps are done you should be able to isolate the problem. :33:
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