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I just reread your previous comment and realised our issues are probably different. Mine only occurs when the actuation arm is right at the extent of it's travel, something that wouldn't happen on the road as the pads would've long contacted the disc rotor.
I'm not stripping mine down anyway; I've opened an ebay return as three of the pad adjusters are rounded off.
Something else I've remembered; once when I stripped a set down previously, I got the cams mixed up. They're different and need to go together a certain way (which is obvious), but if you're rushing it's possible to get them mixed up. I remember this made the brakes feel weird, possibly as you describe. I noticed immediately and reassembled them properly. Perhaps who you bought them off has done this?
macaroon-
I've been using these brakes without an issue for about a year, so I don't think it's been disassembled in the past.
I suspect that the pads being worn down might have allowed the actuation arm to over-extend, even with the rotor in place.
Will update if I manage to find a cause.
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Just had a look and seem to have (hopefully) fixed the problem.
It looks like the worn pads meant that the actuation arm was cycling too far through its travel. After I wound the pads in manually with the 3mm adjusters on the side and released cable tension from the actuation arm it now seems to be working normally again.
I still don't know if I entirely trust it, but at least it's working
Kgrev
I haven't had a chance to look at mine yet, kind of nervous about what I'm going to find.
I'm also trying to work out if I want to repair it. Knowing that it can fail like this makes me a bit unsure. This summer is going to be spent touring, and I don't want to risk it failing when I'm in the middle of nowhere.