Yea i cant figure it out. There is firm pressure after the initial 1 inch of travel. I went through the system again a few days ago and there is no leaks. Here is what i have and done. 2016 brand new m/c, core ss lines, arashi wave rotors, ebc hh sintered pads, and new o rings but not new pistons( the old ones looked good ) the calipers are the 2 pc tokicos. Im running teflon tape on all the bleeders, and Chinese ride it levers, but the result is the same even with stock levers. I cleaned the system with it all apart and not a spec of dust. When the brakes come on its good, its just the travel that is the problem, because by the time they are on the lever is almost touch my knuckles. I had a friend of mine who races and has track bikes come and look at it and he is stumped too. I have been working on bikes and cars since i was 10 and never encountered this. The only thing is maybe from taking it apart so many times the crush washers are worn but there is zero air in there. But i recently found a set of k9 monoblocks and they will be here soon and we shall see whats up. I didnt want to put on the fake brembos that came stock on the newer models and i didnt want the to lay down the cash for some m4 brembos, plus i have heard stories that the k9 monos are just as good if not a bit better. So im interested to see what happens next so i will keep you posted. Sorry for the bad grammer guys. Thanks for your help and comments.
I'm assuming those levers are adjustable, right? I've seen people with adjustable levers have positioned too close and run out of lever travel because the levers hits their knickles or the bar before they can squeeze them on at full brake application. Try adjusting them out some and retesting. I'd be willing to bet that adjusting them out will let you reach full brake pressure before the lever touches.