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A hard pedal with manual disc brakes front and rear could be caused by one or more of the following conditions: The wrong master cylinder.
Manual brakes require the use of a master cylinder with a 1" bore diameter or smaller. If you are using a bore larger than 1" you will have a very hard pedal. Never use a power master for manual brakes. Insufficient pedal leverage.
For manual brakes you will need at least a 6 to 1 pedal ratio. Lower than that will give a hard pedal. | Pedal Ratio | Bore Size | lbs input | PSI out | | 6:1 | 1 1/8 | 75 | 453 | | 6:1 | 1 | 75 | 573 | | 6:1 | 7/8 | 75 | 748 | | | 5:1 | 1 1/8 | 75 | 377 | | 5:1 | 1 | 75 | 477 | | 5:1 | 7/8 | 75 | 623 | | | 4:1 | 1 1/8 | 75 | 302 | | 4:1 | 1 | 75 | 382 | | 4:1 | 7/8 | 75 | 499 | |
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