i was wondering if anyone else has the problem with there brake lever not working properly. iv got an 02 500,and every time i go riding and i hit the brakes, theres nothing there. ive taken it in 6 times already to have them fixed (everytime was under warrenty) and when i get out riding for about 10 minutes i loose my brakes. everytime they fixed it they rebuild the lever.(new rubber seal). finaly i told them to put a new lever on ,one from a 2004 bike. well they said that it didnt work and rebuilt mine AGAIN. so im just wondering if anyone else has this problem. oh, yes they have been blead so there isnt any air in the line.

 

Are you talking about the lever just going to the hand grip on the bar and no pressure or do you have pressure and the brakes just don't stop you? Makes a big difference.

 

the lever goes to the grips. there is a rubber piston in there(i changed it once myself) and it acts like the fluid passes right by it. kinda like it has a rip in it or something. either way though everytime i get it back, the brakes never last long. no pressure.

 

Two thing cause this problem and since you done several rebuilds either the housing in bad or you have a bad wheel cylinder. Does the system loose fluid? If it does it could be a wheel cylinder. If not then the the master cylinder is screwed and it was stupid of the dealer not to replace it after rebuilding it once.

 

no fluid is lost, but i am going to request a whole new assembely. the type that i have since the newer ones wont fit. perhaps there is a metal shaving that some how got in there and its rubbing through it.?? i dont know!!

 

Could have a crack, improper machining or other flaw. It's really not relevent though, it's bad and needs changing out.