Just the Opposite
I realize this is an old thread, but I'm having just the opposite problem. I recently powder coated my levers and reinstalled them. Took a short ride to see if the new coating was thick enough to bind anywhere and it wasn't. No scratches within the housing at all from breaking use. Just the same, I dremmelled it down a bit near the pin. For some reason, my initial pull on the lever gives the normal amount of travel. The following pulls are very tight and short. The bike still breaks properly, but engages sooner like grabbing a handful of front break. I didn't do anything with the calibers, resouvoiur - just removed and reinstalled the lever. Have no idea what I did. Local Stealer just as mistified. Suggested I bring it in....heh.