Argghh. Brakes!

[Fallout]

Ok, so after hours in the garage, hours drive to and from Laurie's house to borrow his wheel, playing with discs and wheels to figure out warp issues, buying a new spindle and new wheel, I think I still have the same issue. Stupidly, I assumed it was the warpage because when I measured it, the disc was moving a full 1mm where as the recommended max warpage is 0.3mm. But after having a go with Laurie's wheel, I think the issue is elsewhere.

The brake lever basically clicked along. Pull it a bit, then resistance, then snaps on further, then resistance, then clicks on further again. It does this when stationary, so basically I've plebbed it all up and it can't be anything to do with wheel alignment or discs. It has to be with either the lever itself, the master cylinder piston, the callipers, or a small vole that lives in the handle bars.

Any thoughts on what to so next, bearing in mind I have to get it all done by tomorrow for the ride out. I have a callipers seals rebuild kit, bleed kit (one way valve on it to make it easier to bleed myself), and 1 litre of Castrol DOT4.

What should I do first?

[Thunderace]

Would you like me to pop over and have a play?

[Fallout]

Mate if you're free, come round! We can drink cider and **** around in the garage. The mrs isn't even in, so we can wear her underwear too.

[Mark_h]

Mate if you're free, come round! We can drink cider and **** around in the garage. The mrs isn't even in, so we can wear her underwear too.


Your mrs is round here and it appears she left all her undies behind today ;)

We've been having a giggle about your excessive wobblyness in the front end dept.

[Fallout]

She's just scouting your house prior to me burgling it.

[Littlepeahead]

Sell it. Get yourself a nice Curvy SV instead. This one looks good.

http://www.ebay.co.uk/itm/2001-Suzuki-SV-650-S-Superb-condition-/150881778437?pt=UK_Motorcycles&hash=item2321413b05

[Thunderace]

Sell it. Get yourself a nice Curvy SV instead. This one looks good.

http://www.ebay.co.uk/itm/2001-Suzuki-SV-650-S-Superb-condition-/150881778437?pt=UK_Motorcycles&hash=item2321413b05

LOL!

[Fallout]

That LPH needs a good spanking.

[Spank86]

I'm busy right now but I could probably spare some time in a week or so.

[Sid Squid]

Grease the lever pivot and examine the pivot bolt for damage, and also the stub end of the lever for wear where it contacts the master cylinder piston.
The piston makes a linear movement, however the lever rotates about the pivot bolt meaning the stub makes a wiping movement across the end of the piston, commonly wearing flats on it.
As you pull the lever the flats drag across the piston in a notchy manner, not unlike that you're describing.
If the damage isn't too great you can effect a fix by carefully reprofiling the lever to a neat smooth curve - don't take too much material off or the lever can become loose at rest.

[Thunderace]

Grease the lever pivot and examine the pivot bolt for damage, and also the stub end of the lever for wear where it contacts the master cylinder piston.
The piston makes a linear movement, however the lever rotates about the pivot bolt meaning the stub makes a wiping movement across the end of the piston, commonly wearing flats on it.
As you pull the lever the flats drag across the piston in a notchy manner, not unlike that you're describing.
If the damage isn't too great you can effect a fix by carefully reprofiling the lever to a neat smooth curve - don't take too much material off or the lever can become loose at rest.

Its fixed, someone had greased it and it got all gobbed up with sh*t, removal, fairy liquid, re-fit, boom working brakes!;)

[Fallout]

Yeah, the grease was the problem itself. It has been greased where the lever slides around in the housing and was causing it to stick because of the road dirt the grease had picked up. I think a bit of WD40 in there now and then will do the job. :)

[Viney]

And here endeth the lesson. Start with the simple stuff first

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[Mark_h]

Maybe time to get the Ace to come see if he can sort my scooter brakes then. Simply seized piston, glazed disc and underwhelming ability of something that would pass as a rear brake set-up on a real bike trying to shift 12 year old fluid. Oh and every nut, bolt and screw corroded into place with each nut, bolt and screw head torsional stiffness being modelled on the finest ripe brie on a warm summer day.

Having digested this thread I've tried covering the disk in WD40 and the tyre in washing up liquid but if anything it's made it all slightly worse but very bubbly. Next I'll send the plastics off to the local chipshop for a respray, run some injector cleaner through the indicator flasher and obviously change the reg/rec.

Luckily the rear brake is magnificent!

Equally lucky is the fact that it rarely goes quick enough to need significant braking.

[Jammy]

Was going to say mark, you could probably drag your feet and get adequate braking force

[Mark_h]

As opposed to the "chuck it sideways at the tarmac" method?

It's amazing how much no brakes, no power and questionable suspension improves your forward planning. I think one ride in 10 should be on something like my mighty Epicuro just to keep your skills sharp. Then when you get on something with much better (or in some cases marginally better) brakes, power and suspension you can apply your improved planning skills more productively.

[Spank86]

But if you plan ahead you miss all the fun.

[Littlepeahead]

And here endeth the lesson. Start with the simple stuff first

That's a bit unfair Viney, Fallout is a bit dopey at times but calling him a simpleton is going too far.