SuzukiSavage.com - Front brake lever release force?

Keifer

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Front brake lever release force?
04/25/20 at 14:00:56

Hi, quick question. I replaced the front brake light switch, it works properly, but the lever doesn't have enough 'strength' when released to press the microswitch fully. Which causes the brake light to stay on.

Is the return force (full released position) pressure for the front brake lever supplied by the spring in the master cylinder? Or fluid? Would rebuilding the master cylinder help this? I just need enough pressure to press the microswitch... Or maybe there's a way to get rid of the 'play' at the end of travel so it will press the switch. Thanks all

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93 Savage - 21K miles

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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2625 Amongst the Twisty Roads	Re: Front brake lever release force? Reply #1 - 04/25/20 at 14:51:54 Is the lever not returning to its resting position? Is the bolt over tightened?
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Keifer Junior Member Offline SuzukiSavage.com Rocks! Posts: 66 Canada	Re: Front brake lever release force? Reply #2 - 04/25/20 at 16:17:11 If anything, it’s loose. It returns to full release, but at the end there is not enough force to press the brake switch (to turn off the brake light). There’s loose play at the end of travel. You have to press out on the lever to press the micro switch.
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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2625 Amongst the Twisty Roads	Re: Front brake lever release force? Reply #3 - 04/25/20 at 16:55:45 There is a spring between the plunger and the lever, is that in place? The spring returns the lever to its resting position. The switch may not be installed correctly if it is not turning off the light with the lever at rest.
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Keifer

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Re: Front brake lever release force?
Reply #4 - 04/26/20 at 13:52:30

Gary_in_NJ wrote on 04/25/20 at 16:55:45:

There is a spring between the plunger and the lever, is that in place? The spring returns the lever to its resting position. The switch may not be installed correctly if it is not turning off the light with the lever at rest.

Is there another spring between handle lever and plunger? The only one on the parts fiche I found is in the master cylinder.. which means I might as well replace it if I have to take that out, right?

Also, what do you think about a bit of corrosion around the dust seal in the caliper? I don't wanna replace the whole caliper body just for that... The rest of the bore and piston looks good. I was hoping new seals and it might be okay. (it never leaked before it was just seized)

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Gary_in_NJ

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Re: Front brake lever release force?
Reply #5 - 04/26/20 at 14:14:37

Sorry, I was thinking of one of my other Suzuki’s, the LS650 doesn’t use that return spring. So you are saying the the lever returns, but it is still putting pressure on the switch? Is the switch activation arm shapped that it is always in contact with the switch? Is this an aftermarket lever or switch? It’s possible that it just isn’t correct? I’ve experienced that before with levers.

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LS650 Cafe, DRZ400SM, FZ6N, SV650S, CB900C, Ducati ST2, CB550F-SS
My LS650=> http://suzukisavage.com/yabb2.2/Attachments/Left.JPG

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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Front brake lever release force? Reply #6 - 04/27/20 at 09:46:21 Keifer , It was seized? how did you free it? did you change the brake fluid or check the level? Are the brakes bled? any air in the system will not allow the lever to fully return ,that may be your problem, not the switch or lever.
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Keifer Junior Member Offline SuzukiSavage.com Rocks! Posts: 66 Canada	Re: Front brake lever release force? Reply #7 - 04/28/20 at 05:38:55 This lever problem was before I dismantled the system. But I’ve now taken apart the caliper, just waiting on new piston seals and a new master cylinder and will refill/bleed with new fluid. Will report back if it’s not fixed...
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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Front brake lever release force? Reply #8 - 04/28/20 at 12:29:34 You may want to use a new/stainless, brake line as well.
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MarcosS40 Junior Member Offline SuzukiSavage.com Rocks! Posts: 51 N. Central PA. Gender:	Re: Front brake lever release force? Reply #9 - 04/28/20 at 13:37:41 batman wrote on 04/28/20 at 12:29:34: You may want to use a new/stainless, brake line as well. You can say that again! I just replaced my 14 yr. old brake hose on the s40 with stainless and it made a world of difference in braking force and feel.
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Keifer

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Re: Front brake lever release force?
Reply #10 - 07/08/20 at 12:32:23

Okay, new master cylinder, stainless brake line from HEL, I'm stoked it's all working great, no leaks! That trick of somebody's (sorry I forget who to give credit) about using a syringe to fill from the bottom up worked fantastic. Primed the MC and the bleeding was super easy...

Couple quick questions: Take a look at my photos below. Which way does that darn speedo oil seal go?? Metal ring flat side up or down? I guessed up, since that is the side that will be against the spinning cable...

For the rear brake, should the cam lever at the back always be under tension from the cable? In order to make it so the pedal travel is reasonable for brake actuation, I had to adjust the cable to pull constantly on the lever. The pads have lots of life left I checked. I'm just not sure how a drum brake should be set up (still a newb here).

Thanks again

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Keifer Junior Member Offline SuzukiSavage.com Rocks! Posts: 66 Canada	Re: Front brake lever release force? Reply #11 - 07/08/20 at 12:32:42 image 2
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Keifer Junior Member Offline SuzukiSavage.com Rocks! Posts: 66 Canada	Re: Front brake lever release force? Reply #12 - 07/08/20 at 12:33:05 Does this look right
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