I am having a bit of a problem with my sierra brake master cylinder.

When I press the pedal, there seems to be around just 2-3cm of travel at the top of the pedal, maybe less than a centimetre movement of the piston. I am almost certain its not right!

There is a solid stop at the end of the travel, like something is in the way. I haven't fitted the brakes yet so the problem isn't with bleeding. I had reconditioned the unit, and when I looked there was no visible damage.

Before I do something I will regret, are there any suggestions to what the problem could be?

I was just wondering how much travel people seem to get on their setup?

Thanks,

James

How far up/down the pedal is the pushrod pivot point from the pedal pivot point?

If it's too high you miht be generating too mush pushrod travel (and too little pedal leverage). Ideally you want the pushrod pivot point as close as possible to the pedal pivot point to maximise mechanical leverage when you push the pedal - this will increase the travel, but give better brake feel. Obviously there are limits as to the angle you can operate the pushrod at without damaging the master cylinder though!

Any pics of how you have it set-up...?

Sorry for the slow replies, I am in town (lancaster) getting some bits and bobs.

I don't think the pushrod is jamming at all. Its all a bit odd really. Its not a matter of where the pushrod enters either I don't think - it goes horizontally straight in, and there isn't too much effort needed to push it in, just the spring. I will dissasemble the m/c and post some pics if the problem isn't obvious.