Master cylinder lever return - Kawasaki ZX-10R.net
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post #1 of 14 Old 06-10-2007, 08:18 PM Thread Starter
 
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Master cylinder lever return

I purchased a used 636 M/C online. I installed it with Galfer lines. For some reason the brake lever doesn't return. When I squeeze the lever, I have to pull it back out by hand (doesn't automatically return). I know the system has to be bled (which I already started to do), but so far the lever still doesn't return on it's own.

Is this normal for a radial m/c install, or did I get funked?

Thanks for reading.
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post #2 of 14 Old 06-10-2007, 09:17 PM
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Either you dont have a return spring in it or there is a blocked vent.

Take the cap off remove the diaphragm and see if it returns.

If it still doesnt then leave the bleeders open on the calipers and see if it returns, if it doesnt then the spring is broken or missing.

OR

You are nowhere near bled on the system and you are still pushing the pistons out whilst pumping, it should still return a little.
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post #3 of 14 Old 06-10-2007, 10:16 PM Thread Starter
 
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Thanks for the reply.
I will be back at it again tomorrow with your suggestions.
Is the spring you speak of part of the plunger assembly # 43020 in this diagram?
http://www.ronayers.com/fiche/400_05...par ent=13420
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post #4 of 14 Old 06-11-2007, 02:06 AM
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Make sure the lines are not binding ANYWHERE with the master.

Sergio
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post #5 of 14 Old 06-11-2007, 09:42 AM
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Quote:
Originally Posted by danno View Post
Thanks for the reply.
I will be back at it again tomorrow with your suggestions.
Is the spring you speak of part of the plunger assembly # 43020 in this diagram?
http://www.ronayers.com/fiche/400_05...par ent=13420
There should be a spring at the end of the plunger to ensure the plunger gets pushed past the reservoir orifice , this in itself returns the lever back.

Also check, lock to lock on your steering to make sure you are not pinching a line anywhere.
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post #6 of 14 Old 06-12-2007, 09:44 PM Thread Starter
 
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Bled the brakes and the lever is nice and firm. the only problem is that since the lever wont return, the brakes are locked up until I manually move the lever back out.

Well, I took the m/c back off and removed the lever. When I push the plunger in by hand it returns. Something must be wrong with the lever. I just bought it from a local shop. Instead of ordering me the oem they got me the LP version. Either the build quality of this lever sucks, or I need to greese it up. I will probably order another one because I would hate for the brakes to lock up on me.

Also, before I removed the m/c, I noticed that when turning the bars to the left, it would hit the fairing up by the windshield. Has anyone come accross this?
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post #7 of 14 Old 06-13-2007, 12:15 AM
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Try reinstalling the lever and dont do up the pinch bolt, maybe it is getting squished.
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post #8 of 14 Old 06-13-2007, 12:24 AM
 
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Quote:
Originally Posted by danno View Post
Also, before I removed the m/c, I noticed that when turning the bars to the left, it would hit the fairing up by the windshield. Has anyone come accross this?
Yes. Loosen the assembly and rotate slightly until clearance is obtained.
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post #9 of 14 Old 06-13-2007, 05:06 PM
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A twist in the line can cause the system to lock, you can apply pressure through it but acts like a one way valve and holds pressure in the caliper.

Make sure your routing is good ,lock to lock.
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post #10 of 14 Old 06-13-2007, 09:45 PM Thread Starter
 
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thanks y'all. The problem was the lever. swapped it with the slightly bent lever, problem solved. I'll probably look into some Pazzo's or something.
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