Hello from Carlsbad, CA

[Hellion]

The brake caliper rides or floats in the "C" shaped bracket and once you remove one half of the caliper, the rest should slide out sideways unless there is a frame member or something else in the way.

Is it possible the caliper is stuck in the bracket from ... corrosion, sand and pebbles or it's just jammed in there sideways or something?

The initial problem might indeed have been adjustment because your brake pads looked so good. I think these need manual adjustment every now and then to keep the pads in close contact with the disc. Part #3 and #4 are what you use to adjust the brake. I think we glossed over that but perhaps the disc rotor is to blame as well. It could be "glazed over" and no longer an ideal friction surface...

 

[panchothedog]

I had to pull the rear axle to get mine off completely. No other way that I could see to get the disc out. Kind of the reverse getting it back in. And yes the caliper is designed to float ( somewhat freely ) in the mount.

 

[Hellion]

You have to adjust that pin just right. Just barely loose when no pressure is applied.

This guy is RIGHT and go kart brakes of this type mimic automotive disc brakes in which the brake pads are in constant contact with the disc or rotor. What I mean is, the brake pads are lightly dragging on the disc/rotor at all times, unlike drum brakes. It is this way so that when you do hit the brakes, there is basically no slack that has to be taken up before you have direct braking action.

Have I mentioned that I am an average YouTube mechanic at best.

If you did mention this, I think it went unnoticed. Since you are "average", I think a small floor jack, if you don't have one, is essential for work of this type as you can lift the kart up and get under there, put your OEM Eyeball, Mark 1 on the once-hidden parts of the kart and see what is preventing you from taking it apart. It's also great for changing riding mower blades and for jacking up your car of course ...

 

[panchothedog]

For working on karts, floor jack ( even a marginal one ) and 4 car stands, and you can put that sucker right where you want it. At a comfortable height. Makes a long afternoon so much more pleasant.