Front Brake Lever Not Returning Forward - Kawasaki KLR 650 Forum
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post #1 of 3 Old 02-04-2019, 04:31 PM Thread Starter
1st Gear
Join Date: Jan 2019
Posts: 21
Front Brake Lever Not Returning Forward

Guys, Iím still trying to figure out my 1989 250. My front brake lever has about an inch of free play which is enough to engage the rear taillight without actually pulling the lever enough to engage the brake. Itís like the lever is not returning forward enough or that there should be some kind of pressure or force to make it stay in the all the way forward position. Iíve looked at the schematic and canít see anything like a spring or something that pushes the lever back forward again. Am I missing something? The brake fluid reservoir is 3/4 full on the sight glass when the bike is level.
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post #2 of 3 Old 02-09-2019, 02:26 PM
Join Date: Feb 2019
Posts: 9
theres a piston in your front master cylinder that pushes the fluid to engage the caliper. that piston is probably seized. it probably needs a rebuild.
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post #3 of 3 Old 02-09-2019, 07:21 PM
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,609
The piston assembly #43020-1065 has a spring on its interior base. Corrosion of the bore must be preventing the piston cup & shaft from extracting completely from the bore.

Can you see this parts schematic?

Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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