My broken brakes.

c_dug · Super Spammer Joined: 04 Sep 2007 Karma :

My brakes are broken!

I was off all last week getting the sv up to scratch and the diversion repaired from its crash and now tomorrow I have to get a train to work because the back brake of the sv shat it's pads half way home from work today and the diversion is constantly showing the brake light from the front leaver.

I can deal with the sv issue, new pads and pins, I could do with some advice with the diversion though.

I recently fitted a tdm900 reservoir/master cylinder to match a set of blue spots up front and I'm not sure if there is an issue with the master cylinder or an issue with the switch itself. The issue is that when I release the brake the piston doesn't seem to push the lever far enough back to click the microswitch. The switch is compressed about half of its travel, but it doesn't click for another mm or so.

I'm unsure if the master cylinder should be releasing further than it is, or if the microswitch should be clicking earlier. So my question is, should the master cylinder push the switch all the way back in with ease, or should the microswitch be clicking quite early in its travel?

I've taken a couple of videos to show better what I mean but they're being very slow to upload, I'll pop them up in a bit.
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I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.

Pete. · Super Spammer Joined: 22 Aug 2006 Karma :

The easiest way out of that is to junk the switch and buy a pressure-switch banjo bolt for the front brake hose. This puts the light on when it detects pressure in the system, as you apply the brake.

EDIT: or glue some packing to the lever to press the switch earlier.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good Very Happy

c_dug · Super Spammer Joined: 04 Sep 2007 Karma :

I've no real problem with that but if I've bought a faulty part I may as well get it replaced. If it's just the switch I'll buy one but if the master is dud I'll try for a refund or replacement.
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I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.

gavcarter · Could Be A Chat Bot Joined: 28 Mar 2009 Karma :

Pete. · Super Spammer Joined: 22 Aug 2006 Karma :

P.addy · Red Rocket Joined: 14 Feb 2008 Karma :

I'd have removed the wires for the front brake light and remembered to use the rear as well as the front. Quick fix really.

But yeah, the CBR600RR had the same issue, glued small piece of material as padding, voila.

davebike · World Chat Champion Joined: 15 Nov 2013 Karma :

This issue is caused by a very slightly the wrong Brake leaver
The master cylinder accepts several different leavers some have very slightly different arms to work the brake switch

The cure is either the correct leaver (very hard to sort out) or a little packing on the arm the works the switch

Dave
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c_dug · Super Spammer Joined: 04 Sep 2007 Karma :

The lever came with the master cylinder, I presumed perhaps incorrectly that it was the standard tdm900 lever.

I thought that it worked fine when I first fitted the brakes to the divvy but it's possible I just hadn't noticed the issue. Sounds like it isn't all that uncommon anyway. I guess if there is no real issue with the master cylinder I'll just add a bit of something to the lever then.
____________________
I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.