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locked front brake

Kevin.NZ

Kevin.NZ

High Miler
GT Famiglia
Joined
Jun 17, 2009
Messages
808
Reaction score
438
Location
Howick, Auckland, New Zealand.
I went for a short ride on the Breva last Saturday, and it was very short , after about 5 Kms the front brake started to lock on, I could feel the bike getting more sluggish and pulled over. When I stopped, the wheel was locked solid, and the brake lever was hard, fortunately I had tools on me and undid the front bleed nipple to relieve the pressure and got the wheel free and drove home slowly not using the front brake. I checked almost everything, both wheel cylinders, nothing was seized, operated the lever a 100 times, even bled the brakes and I couldn’t replicate the fault. I went out again the next day and the same thing happened. When I got home I went over everything again and then remembered I replaced the front brake lever and thought it could be different from the original, I took it off and it was identical, but the tiny pushrod and spring that activate the master cylinder never fell out like it use too. On close inspection one coil of the spring had flipped over behind a circlip in the master cylinder and was operating the brake about 0.5mm. This was enough to stop any brake fluid returning to the master cylinder. The penny should have dropped earlier when I couldn’t push all 4 pistons back into the wheel cylinders, I pushed 1 and 3 came out. When the brake disc got hot the fluid expanded and applied pressure to the brakes where it got hotter etc. But why did this happen, I must have dislodged the pin/spring when changing the lever, also about a year ago the dust seal perished and I removed all of it to stop rubber getting into the cylinder, it turns out there is a lip on the seal that holds the spring in place, I have now put in a suitable size washer inside the master cylinder which will stop this happening again until I can source a Brembo dust seal.
Kevin
 
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