Brake lever travel change

[suzukizone]

Greetings, Just rebuilt my 81 GS 850 G front calipers. Had been planning this since I rebuilt the master cylinder/piston some years ago. Brakes were working quite well except for a "click" when hitting the brakes. All new seals, rubbers, shims, the works after total cleaning of all internals.

Now the brake lever comes in closer to the handlebar before I get full pressure, Bled system very thoroughly several times but no improvement. Figured at worst there would be no improvement. Lever is not mushy, same as previous but just want it to engage further out like it used to. Only worked on the caliper assemblies, not the master cyl, except to top up fluid as I pumped through & bled.

Any ideas?????

Thanks for all the previous assistance & advice I have rec'd over the year BTW.

DH

[txironhead]

The master cylinders are prone to have an air bubble trapped in the upper banjo fitting. Try tapping on it with a screwdriver handle as you're bleeding the brakes.

[suzukizone]

Brake lever travel change

Thanks for your prompt reply.

I am familiar with that issue & that is the first position I bleed a system from, working my way methodically through each & every junction down the line, tapping away like the Count of Monte Cristo in the dungeon and bleeding each junction bolt finally to to the bleeder nut.

Like I said the lever is firm, not an air issue but a sudden longer pull to get to the firm pressure point with no "softness: in the action.

But thanks for your input, any other takers?

DH

P.S. Bike is Black :-D

[oldschoolorange]

you could have a piston coming back farther than it normally would and this is causing the strange brake lever feel. Who knows, this could be the way they are supposed to feel and you are used to having sticky pistons

[suzukizone]

Brake lever travel change

Thanks for your reply oldschoolorange. That had crossed my mind. Only concern is I don't have the leverage I did previously with the lever now engaging further back I notice braking is not as good because of this. Hope I am explaing this clearly.
One of the problems I found when I did the job was the rubber sleeves that were on the slider bolts had swollen to the point I had to pull the bolts from the housing by clamping them in a vise & fighting them off. The replacement sleeves let the slider bolts slip in & move smoothly. Piston & seals actually looked quite good & probably didn't need attention tho glad I did it. The lands for the seals were crudded up a bit & they got cleaned out completely.
Thanks again for your input.

DH