Strange brake issue. Lever is TIGHT!
1996 300FW. I recently went through it and everything works perfect. Except the front brakes. The brake lever has very little if any pull. The brakes are "on". I rocked the machine and you can feel the fronts grabbing. Funny thing is sometimes the brake lever will move about 1/4 inch and then the brakes grab. 4-wheeler is not being used. This is all in my garage, different temps.
This 4-wheeler has not seen much work in its life. The brakes are near perfect. Shoes are original and very little if any wear. I emptied the master cylinder and then filled it again with fresh brake fluid. Then bled the brakes until clean brake fluid was coming out. The adjusters are all backed off as much as possible. With the drums off the brake lever moves as it should and pushed the shoes out. With the drums on, very little and at times no movement of brake lever and the brakes are working.
Strange to me why it does this. I'm leery of spending any money on the drum brakes as I think its more cost effective to just do the disc brake conversion. But I'd of course rather not spend any money and these brakes look perfect!
Could a brake cylinder be getting hung up? Any ideas?