[Bryan]

I have a very soft brake lever. When first pulled, it will go all the way back to the grip. It can be pumped up a few times and that improves matters for a short bit, but soon it will return to its original wishy-washy feel. It's not safe the way it is, and I would sure like to correct it. Here is what I've done thus far:



1) New USA Motrocycles Master Cylinder

2) New Stainless Brake line from JDA Enterprises

3) Polished caliper piston

4) New caliper seal - Honda OEM

5) New Caliper rubber dust cover - Honda OEM

6) Completely cleaned caliper

7) New bleeder, sealed with teflon plumbers tape



I have bled and bled and bled - there is NO air in the system. It seems that all would be well if I had another inch of brake lever travel. (Perfect straight line for someone.) My wife is getting a tad upset that I have spent as much as I have, so hopefully it's a fairly simple fix.



Any ideas from the gurus? Or Nagus?

 

[Bryan]

Thanks for the suggestions. After spending some time with it yesterday I am inclined to believe the problem is in the caliper. Either the caliper pins or the holes they go into might be worn. When I squeeze the lever the lever still goes all the way to the handlebar, but when I do this and look at the caliper, I can see it moving sideways away from the rotor a good half inch or a bit more. The bolts are tight, so I think it may be in this area. Does that make sense?

 

[Bryan]

Also, if the piston inside your caliper was squeezed all the way back, it will take a lot of pumping to get the pads to grip the rotor. The calipers are self centering, so the guide bolts need a little grease on them to allow the caliper piston to "center" the rotor between the 2 pads.



Does that make sense?? The piston pushes the pad on one side, until the pad touches the rotor, then, the "whole" caliper moves the opposite direction to pull the other pad to the rotor.

Yes, it does make sense, and I appreciate the thoughts. Looks like there are still a few things to try. I'll let you know when it's fixed and what was messed up.

 

[Bryan]

FINALLY sorted it out. Well, not me but a local expert in all things motorcycle. It seems the shims that lay on top of the pads were somehow binding slightly, enough to cause the brakes to drag. All is good, and I'm back on the road. Thanks to all of you for your thoughts, ideas and suggestions.