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Post Info TOPIC: Excessive brake lever play


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Excessive brake lever play
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Hey all,

I can't seem to dial in the free play and reach of my front brake lever. Even with the reach adjustment dialled in as close to the bars as possible the lever still sits far out. And there's so much free play that the lever hits my knuckles when using the brakes.

Here's a video showing the issue: https://youtu.be/LC0BdVWTrtw

Is the lever not the correct one for the bike? Seems like the gap between the master cylinder piston and the base of the lever is too big?



-- Edited by robject33 on Sunday 14th of April 2024 11:31:02 AM

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Reading, UK | '93 Open Enduro TTR 250



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It's not a standard lever, but I think your issue is you are missing a threaded rod that should screw into the lever and make contact with the piston. This should be adjusted so that it has 0.5mm - 1mm gap between it and the piston at rest.

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Thanks for the reply. It does look like that's what's missing from looking at pictures of other levers. Problem is, this lever doesn't have a hole for the threaded rod to go through... Have ordered a replacement lever now, I'm pretty sure that will fix it!



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Reading, UK | '93 Open Enduro TTR 250



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A new lever will only fix it if you have bought the correct one!

Back in the day, a lot of TTRs passed through my garage doors and almost every one had an ill-fitting after-market lever (or levers) fitted. I ended up with a bag of about 30 non-TTR levers which I recently sold on eBay. That was after I had binned all the bent and broken ones.

It took me many tries to find affordable after-market levers that fitted the TTR properly but I got there in the end and they are the ones that Steve currently stocks in the Totally TTRs shop here and here.

You don't have any information on your forum profile so I can't tell if you are in the UK or not but, hopefully, that may help anyways. 

Brian

PS If you can put some info on your profile even if just your first name and country that would be great wink



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TTRfan wrote:

A new lever will only fix it if you have bought the correct one!

Back in the day, a lot of TTRs passed through my garage doors and almost every one had an ill-fitting after-market lever (or levers) fitted. I ended up with a bag of about 30 non-TTR levers which I recently sold on eBay. That was after I had binned all the bent and broken ones.

It took me many tries to find affordable after-market levers that fitted the TTR properly but I got there in the end and they are the ones that Steve currently stocks in the Totally TTRs shop here and here.

You don't have any information on your forum profile so I can't tell if you are in the UK or not but, hopefully, that may help anyways. 

Brian

PS If you can put some info on your profile even if just your first name and country that would be great wink


 

Luckily I bought one from Steve and it arrived earlier in the week! I've just fitted it and it's made a huge difference. No idea how the previous owner was riding the bike with that old lever. On the new lever I have had to wind the adjustment screw all the way in though, so I think the piston bit on the master cylinder might mot be returning far enough. I see there's a rebuild kit on the totally TTRs shop, but it's £50 so for now I might have a go at dissassembling, cleaning and reassembling and see if that helps. 



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Reading, UK | '93 Open Enduro TTR 250

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