Question about 2003 kawasaki Z 1000

3 Answers

My 2003 z1000 A1H has a lot of front brake lever travel. basically it somes all the way back to the bar on heavy braking and on normal braking it comes back and hits my fingers which is dangerous as i cannot apply an more brake when needed. Ive changed the pads and levers and this has not solved the problem. The discs have loads of life left. Ive changed the brake lines on my zx10 before but this doesnty see to make much difference on kawasaki's. Is there anything else i can do to reduce the lever travel? thanks

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  • rob_farquhar Jun 07, 2010

    My 2003 z1000 A1H has a lot of front brake lever travel. basically it somes all the way back to the bar on heavy braking and on normal braking it comes back and hits my fingers which is dangerous as i cannot apply an more brake when needed. Ive changed the pads and levers and this has not solved the problem. The discs have loads of life left. Ive changed the brake lines on my other bike which is a zx10r but this doesnty see to make much difference on kawasaki's. Is there anything else i can do to reduce the lever travel? i have bled the brakes and changed the fluid yes and by a dealer also. this has not however solved the issue. im worried as its really dangerous and ive got a 2 up trip with my girlfriend to the alps in 2 weeks.

  • rob_farquhar Jun 07, 2010

    My 2003 z1000 A1H has a lot of front brake lever travel. basically it somes all the way back to the bar on heavy braking and on normal braking it comes back and hits my fingers which is dangerous as i cannot apply an more brake when needed. Ive changed the pads and levers and this has not solved the problem. The discs have loads of life left. Ive changed the brake lines on my other bike which is a zx10r but this doesnty see to make much difference on kawasaki's. Is there anything else i can do to reduce the lever travel? i have bled the brakes and changed the fluid yes and by a dealer also. this has not however solved the issue. im worried as its really dangerous and ive got a 2 up trip with my girlfriend to the alps in 2 weeks.

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3 Answers

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  • Master
  • 389 Answers

Hello, my name is Ben. Even though I see no mention of it in your question, you seem to know what you are doing so I will assume you bled the brakes and that didn't help. This leads me to believe your problem is in the front master cylinder. Sometime in the past it may have been re-assembled incorrectly or some of the small rubber pieces are simply worn out. I would suggest carefully dis-assembling the front master cylinder and examine the plunger and all passages for signs of wear or blockage. I believe this is the most likely source of your problem. You can buy master cylinder rebuild kits, or you might just need to replace the entire unit. You are correct to be concerned since properly used the front brake is the greatest stopping power on your motorcycle and you know what happens when the rear wheel locks up. I hope this helps with your repair, Ben.

Posted on Jun 07, 2010

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  • kawasaki Master
  • 19,396 Answers

Hi.

Did you check the master cilinder?

Check also thet the problem is not the lever itself (I know it had been replaced). Check the lever pivot bolt.

Check that the pistons are well greased and not worn.

Ensure that you have bleed the lines properly, without leaving any air in the lines.

Check caliper and distance between the pads and disk.

See also the general article here. It can help a bit to understand your bike break system.

Posted on Jun 07, 2010

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  • Master
  • 6,966 Answers

Hi and welcome to the site,

Would the travel distance be lesser if you pump the front brakes?

Initially, possibilities to consider:

  • low brake fluid level;
  • presence of air bubbles along the brake line.

Offhand, have you tried bleeding the front brakes? If air bubbles present, leave the front brake lever pulled (use a tie strap) overnight.

Good luck and thank you for asking.

Posted on Jun 07, 2010

  • rob_farquhar Jun 07, 2010

    i have bled the brakes and changed the fluid yes and by a dealer also. this has not however solved the issue. im worried as its really dangerous and ive got a 2 up trip with my girlfriend to the alps in 2 weeks.

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