Normally when I apply my front brake it engages very quick...maybe a 1/4" pull. A couple times lately it has squeezed about 1/2 way before engaging. Very noticeable difference from normal. No rhyme or reason to when it happens. Very random. Any ideas on what could cause this? Appreciate the help!

 

air in the system?
Try bleeding the system.

 

Pete,

It would be difficult to diagnose your problem or provide a solution over the net. If it were my bike (2000 Heritage) I would rebuild the entire system. Calipers, Master Cylinder, New Crush Washers on the Bango Bolts, Pads and fresh fluid. Additionally, measure the Rotor to insure that meets minimum thickness.

Your brakes are the most important system on your bike.

 

I don't mess with brake problems. Get it professionally diagnosed.

 

Have you checked the fluid level? Otherwise try this trick....pump the brake lever until firm and then hold it depressed while wrapping a bungee cord around the lever AND grip. Leave it like that over night.

 

Had this symptom on my previous bike, 2005 SG. Turned out it was the seal on the caliper piston. When you release the brake the disk kicks the brake pad back but it remains very close to the disk, almost dragging. As the pad wears the piston stays further out of the caliper which is why you have to add brake fluid occasionally.
In my case the piston had gotten some kind of varnish build up on it and it didn't slide through the seal. Rather the seal was adhering to the piston so when I released the brake the seal pulled the piston back, almost like a spring. As the pad wore down the piston and pad were further away from the disk such that you could see a gap between them. It go so bad that I had to pull the brake lever almost to the throttle to get the bike stopped. I pulled the caliper and used some brake cleaner spray and it was back to normal.

 

When was the last time you flushed the system? DOT5 attracts water and compress' differently. Flush, refill and bleed it.

 

I have done and had some work done recently. Changed the brake fluid cover and had the front forks changed to chrome which required the caliper to be removed. Would these possibly have caused the problem?

 

Could, but I think it's coincidence.

 

Every couple years change the fluid . I also take brakes apart clean and lube everything