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Front brake lever

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Ken4004:
Well I am glad to say my front brake is now really good , as soon as the lever is pulled in pressure is felt at the brake lever immediately so all good.
So the issue with the leak was a small scratch inside the master cylinder bore so I polished it out with fine emery paper and flushed it clean.
I bought a better quality master cylinder repair kit fitted it  and then re bleed the brakes which took about an hour, I would say if you pull hard on the brakes now the gap between the brake lever and handle bars is now 40 mm instead of 10 to 15 mm, I believe the movement is due to a little flex in the brake calliper which is to be expected but I just check tightened the caliper bolts so all is good.
So now just have to bed in the brake pads.

I really appreciate everyone advice and hopefully should be on the road once the weather improves , I just need to go over the whole bike again and check everything is tight and correctly assembled ( shake down) I might even take it into the local bike shop and get them to do an MOT test even though it doesn’t require one anymore just in case I have forgotten something better safe than sorry.

I expect like me your all glad this saga is resolved your probably sick of hearing about it.

Rayzerman:
One thing I find occasionally helpful when I feel I've bled as best I could and it still feels a little spongy.... tie the lever to the handlebar, so everything is under some pressure, then tap the lines starting at the bottom (questional benefit, but what the heck)... leave it overnight.  Lever will likely be firm in the morning, meaning air bubbles migrated up into the reservoir.  A quick squirt should confirm no air.

Ken4004:
Hi Razerman while bleeding the brakes I did a combination of tapping the hoses and the continued with the bleeding, I will however have another look tomorrow but it really is very firm at the moment so I think I have cracked it

exvalvesetdabbler:
Well done ken.  Not everyone chiming in to this thread doesn't mean we're not engaged.  We're probably making notes in case it happens to us!

Regarding any micro bubbles left in there, once they get to the top you can usually remove them by just gently working the lever by about  10 cm a few times, you will see them coming out one of the tiny holes in the reservoir.

Regards
Dave

Ken4004:
Hi Dave

Yes I have noticed this already and will keep as you say pumping the lever slightly to encourage the last of the air out of the system.
With regards to the leak I had the scratches I found in the bore were hard to see but luckily not too deep so we’re relatively easy to polish out.
If I replace the master cylinder on any future bikes I will probably inspect the bore surface with a lot more care , this time I also used lint free clothes to wipe all the components and the bore as any imperfections or dirt present will damage the seal.

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