Like many other users I have never really solved the problem of a dragging front brake on my TTR250, I have other bikes but have no problems with the brakes. I could service it, but it would soon start dragging again, wearing out pads & disc. I finally realized the problem could not be solved with the standard setup, so time for a change.
It would be a bit difficult to change the brake caliper unit, so I fitted stainless steel pistons & new seals fitted with rubber grease. I replaced the Master cylinder unit with one off a Suzuki DRZe off ebay, I also have a DRZe so I could compare fitting. I fitted the new Master cylinder using the original hose & bleed the unit with no problem. The slight problem is a DRZe is Enduro exempt, so no brake lights or mirror fittings, so I used a pressure switch & mirror bracket, yep all off ebay.
Result, I finally after nearly 10 years have a normal working front brake that clears with no dragging or spongy feel.
I'm sure any other master cylinder unit from other bikes with a single disc brake, KTM etc with 27mm brake pistons would work equally as well. It may have worked simply by replacing the pistons with stainless but I wanted a result so went for both options.
Thanks Daniel, Just been out for a ride to have my TTR250 MoT'ed passed as per normal. The front brake really felt like riding a new bike, so positive & being a wet day it also gave it a good wet road test, all passed ok. Well worth it, transformed the bike.
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-- Edited by l0k1rider on Friday 14th of July 2023 01:48:29 PM
