Symptoms of front brake master being too small

[chiz]

Hey All
  I was just wondering if you guys have messed around with brakes to the point where nothing is a mystery and know what a master feels like if it is too small to to match the calipers.
  Thanks Lez

[FJmonkey]

When you mean "Small" I am guessing you mean its ability to provide proper braking. The stock master has a 5/8" piston or 0.625 inches in diameter. Others have used a 14mm or 0.551 diameter. Going larger will provide more fluid displacement but requires you to squeeze the lever harder to get good braking force. The smaller 14mm displaces less fluid but allows a less harder squeeze on the lever. I don't recommend going larger than 5/8". And I don't know how much smaller you can go before you don't have enough displacement for full braking. Maybe others have tried smaller master sizes. Then radial masters are another story, and have been used on FJs with success. To answer your question, a master will feel too small when you can squeeze the lever all the way to the grip and not fell it tighten up. Assuming the system is bled properly.

[chiz]

Hi thanks
   I bought this cheap set for my triple yam adjustable lever said it was for 125cc to 400cc   my bad. tried every trick known to eradicate the air. The calipers are off the forks and up at the handle bars now no diff, the lever feels like you are compressing a spring the lever does not hit the wall at all.
    I don't think there is air in the system but have been wrong before.
Lez