brake mysteries - Kawasaki ZX-10R.net
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post #1 of 24 Old 08-18-2007, 08:26 PM Thread Starter
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brake mysteries

ok guys, here goes. i installed my 636 master/calipers about 2 months ago. used it for 2 trackdays, no fade at all either time. bled them thuroughly after the 2nd day. have dot5 fluid in them. stock lines, stock pads. they have been AWESOME from day one. then, wednesday going to work, i go to back down the driveway and almost crash, no brakes. lever went to the bar, no resistance at all. i pumped it up, and it was fine. rode to work, and by the time i got to work (about 3 miles) it was normal. then it was fine for two days. this morning, same damn thing, no lever whatsoever. this time, i pumped it up a lot, it didnt get much better. i rode to work (shouldnt have probably) and it never got to the same feel as before. then when i came out from work to ride home, solid as a rock. coming home on the freeway, with no traffic around, i grabbed a handful of front brake and it was like hitting a wall, just like before this happened. what the hell is going on here?!? i'm ase certified in suspension and brakes, and i have no idea on this!! i suppose my master could be bad, but i've never seen a master be bad sometimes, then just fine, that just doesnt make sense. help me out guys, i'm going to the track in a couple week, wanna make sure i'm dialed in. tia.
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post #2 of 24 Old 08-18-2007, 08:35 PM
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H2O, in the lines? Hydraulic fluid draws moisture. Is the res lid on tight? Are all the bajo bolts tight and sealed?

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post #3 of 24 Old 08-18-2007, 08:37 PM
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Dot 5? Or 5.1?

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post #4 of 24 Old 08-18-2007, 08:57 PM
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The pistons are retracting into the caliper too much at some point, can happen if you get a front wheel shake/tankslapper etc
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post #5 of 24 Old 08-18-2007, 08:58 PM
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Possible air pocket in the crossover line??


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post #6 of 24 Old 08-18-2007, 09:38 PM Thread Starter
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i should have added that everything is totally dry, no fluid leaks anywhere. see, if there was air in the lines, it wouldnt get "better" by sitting. i really am stumped here. i will try to bleed it tomorrow morning.
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post #7 of 24 Old 08-18-2007, 09:40 PM Thread Starter
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Quote:
Originally Posted by technic View Post
The pistons are retracting into the caliper too much at some point, can happen if you get a front wheel shake/tankslapper etc
never had anything like a front wheel shake at all. occasional wiggle in the bars, but thats it! i dont think the pistons are retracting as i can still hear the pads dragging slightly on the rotor. also, the level of the fluid doesnt change, it stays right at the upper line.
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post #8 of 24 Old 08-18-2007, 11:37 PM
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I would guess your pistons are sticking on one of your calipers.


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post #9 of 24 Old 08-22-2007, 10:51 PM Thread Starter
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update:

so last night i bled the whole system. my dot5 fluid had changed from a nice deep purple to a slightly-tinted-purple clear. so i bled it all out, couldnt get the lever back at all. zip-tied it to the bar, came out this morning, got no air out of it. rode it to work anyways, the fronts still stop me, but the lever comes to the bar easily. come out of work and the lever is solid as can be. i start riding, and every time i pull on the lever, it gets a little worse. WHAT THE HELL IS GOING ON? do i need to/can i rebuild my master cyl? i dont know what to do... thanks guys.
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post #10 of 24 Old 08-22-2007, 11:08 PM
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Sounds to me the seal in your cylinder may have gone hard.

Last edited by bkkninja; 08-23-2007 at 02:06 AM.
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