Front brake lever problem?

The front disk brakes on my 1982 KZ750H3 work fine. The lever feels hard when pulled and doesn't need any pumping (no air in system) and all seems fine. Except that the lever pulls in almost to the point of touching the grip! The pads are nearly new so it's not a wear problem. I've tried moving the master cylinder into different positions on the (stock) handlebars, but it doesn't help. Once the pads start to wear I'm afraid the lever will actually hit the grip!

I see no adjustment for this. Any ideas? Thanks!

There's air in the line.

That's what I thought at first, so I bleed them out. No air, and the lever is nice and hard when pulled. Maybe the lever is bent. It was dropped on that side by a previous owner, but the lever looks good.

No eBay APP ID and/or Cert ID defined in Kunena configurationCould be the wrong lever too. If so, here is one for cheap!

As the pads wear, the piston moves outward so it shouldn't change the feel of the lever. Sounds like air in the sytem like above poster said. Good luck.

Open the master cylinder,inspect the two small holes in the bottom for clogging. If plugged, use a wooden toothpick to open them up and try again.

Caution!! brake fluid is a paint stripper, so avoid getting any fluid on the tank/fender.

No, the holes are clear, and as said it is not air in the system (I've bleed a thousand vehicles in my time).

The wrong lever might be the answer I suppose. Wouldn't hurt to change it. Thanks for the link

I could be wrong here but before you order new lever, compare it to clutch lever. Other than how they look at business end they should be identical in appearance. Length, size, taper, etc. Also check where lever contacts master cylinder inside for any wear. A little wear at that point goes a long way in how it feels. Plus, if you rebuilt it, did you just use new seals or a new piston/rod? Wrong kit (piston/rod length?) may be problem? Grabbing at straws here.

Well, I just went out and took a long look at it. I tried bleeding it again and can't produce any air at all. Looked at the master cylinder and the number is right for this bike ('82 KZ750H3).

Now about the lever; As I mentioned, the bike had been dropped on it's right side, so maybe the previous owner replaced the lever with something different. Here's the lever...

It is longer then the clutch lever and of a different shape. It has no Kawasaki number on it at all, just the letter "C" in a circle as seen. For those who have this bike, does this look like the right lever?

Good KZ750 brake lever photos can be found at ebbaayy.