notchy brake lever

[GZXR400]

My front brake has a notchy/ratchet effect to it, It doesent feel good so i took of the lever and cleaned and regreased the area and it was fine lovely and smooth.

Took it out for a ride it was fine then left it a few days and slight notching again, Front calipers were recently rebuilt absolute nightmare.

After the rebuild one side of the right hand calipers was rebuilt again due to leaks. After doing this there was leaks from the banjo connection on the caliper and the master cylinder was missing a copper washer.

So rebuilt with all new copper washers and rebled the brakes

Now iv got this notchy lever problem all iv done so far is clean and regrease the lever and the notchy lever is back.

The only thing i can think of thats different now is the resevoir is at the upper mark and previously i filled it to just under the upper level.

Anything else i can check ? the fluid is new castrol dot 4 fluid

Thanks

[Islander]

First thing to do is to remove and clean the lever and its bush, the pin and the receiver thoroughly and inspect them carefully to see if anything is badly worn/scored or breaking up and causing the effect.

[GZXR400]

i took the lever of and it seemed ok, il go have another look