I have a 2006 Hardrock Sport that I just put Avid BB7 Disc Brakes on the front. Am just wondering how much brake lever travel is considered normal? It seems as if I have to get the brake lever almost touching the handlebar before they fully engage.
Do you have the inboard pad cranked almost all the way out? With each pad being adjustable on the BB7, you should be able to tune lever feel however you wish. There's also a break in period, about 20 to 40 stops, before the pads bed in and provide full power.