If the lever is stuck then I would look at its pivot and if that checks ok then the problem should be in the m/c-probably from crud causing the piston to get stuck. Also, when you say you 'cleaned' the caliper did you disassemble it(remove the piston) or did you just clean the exterior? At this point I would think about blowing everything apart and do a thorough inspection. You can get the caliper piston out by removing the pads and then pumping the brake lever until the piston pops out. The m/c requires a set of snap ring pliers to get it apart but it is pretty straight forward to work on.

 

Yes I removed the pistons and cleaned them, they were in great shape, I pulled them out with my fingers

 

The lever won't move in OR out?

Please correct me if I'm mistaken, but there's nothing that should be preventing the lever from moving back out, even if there's some sort of gum-up in MC or caliper. I'd expect that the lever could just flop back and forth while the brake was locked up, kind of like my clutch lever did when the cable broke. This makes me think there's something wrong with the actual lever.

 

the way i see it is in order for the brake to be on(stuck or held), the lever has to be in, due to the fluid(unless it was just the pads sticking). and due to the fact that the lever locks up i can surmise that the piston is not moving. the only time the brake sticks is when the bike is moving at least 15kph. with the bike not moving the lever and pistons work perfectly. there has to be some sort of binding that holds the pads and pistons in place.

and correct the lever will not move in ANY direction while stuck

 

Sounds like hydro-lock to me, I don't know why this would happen with a brake system. Did you check the tightness of the bolts on the caliper? Maybe you cranked them down too hard.

 

iv figured it out. the hose had a very small kink(unnoticeable) right where it turns into the plastic covering. the reason it only happened when i was going at least 15 was because when i would pull in the lever, the forks compress driving the cord into the handelbars and kinking the hose further.

thanks for everyone's help!

 

Wow! What a find. Mine is kinking at the same place. Made worse by Bark busters pinching it over the top. What did you do about the kink? Replace the line?

 

Yeah I had to replace It. I bought a galfer steel braided line.

 

Thanks. Doing the same.