Front brake

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Ok Gary I got the master cylinder kit today. I understand most of the order except when does the washer go in? On the piston before the snap ring I assume? They also include rubber grease but most of the people online use some brake fluid. Is there a preference?
And the cap sits on top of the spring like this right?
 

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No biggy on that ring. The boot will stay put. I like Valvoline 3-4 synthetic brake fluid. Works in about 95% of brake systems and it's my assembly lube too. Seems to not hurt paint much either.
This ok?
 

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Ok I'm.list again. I cleaned the master cylinder and the caliper followed the instructions perfectly (I think) filled the cylinder an started pumping the brake. It never really got stiff. I kept opening and closing the bleeder as in 4 pumps with bleeder closed. While keeping the brake squeezed I closed the bleeder. I have fluid coming into the bleeder tube but it's not activating the cylinder? Am I missing something?
 

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They can be a real pain on these bikes.
Easiest way I know is to take the caliper loose from it's mount so you can lay it on it's side.
Remove the piston and fill the caliper with fluid, then reinstall the piston.
Rotate it upright so any air floats to the top (the hose banjo) and slowly push the piston back in.
Watch the reservoir don't overfill itself.

What you're effectively doing is pressure bleeding using the caliper to force the air out the top. Sounds a bit flaky... but it works.
 
Yes, it can be hard sometimes to re-fill a completely empty system and get it to build pressure. I start out using a Mityvac vacuum pump to fill the system, then switch to the old fashioned hand pumping to finish. Air bubbles will often be trapped around the MC piston and where the line connects to it. You can often free them up by pulling in the brake lever and letting it snap back open (bleeder valve closed). Do this several times in rapid succession while watching the fluid in the reservoir for bubbles floating to the top. You can also tap on the side of the master cylinder and where the line connects with a plastic screwdriver handle as you pump and release the lever.

Something else you can do on stubborn ones is "back bleed" them, that is, force fluid up from the caliper into the MC reservoir. But you'll need a Mityvac (or similar tool) for that. It has another "port" on it that pushes pressure out. So, bleed it normally until the bleeder hose is full, then switch the hose to the "pusher" port and pump the fluid back in and up into the MC.
 
One last thing. With the front brake now that everything is new is it common that the brake lever is stiff. Very little play. Works perfectly but not much play.
 
I had the front end up. I hand rolled the front wheel and if was moving. Applied brake and it released. Can I use the wire to clear it while it's all together?
 
I had the front end up. I hand rolled the front wheel and if was moving. Applied brake and it released. Can I use the wire to clear it while it's all together?
Yes if the lever is not pushing on the piston at all.
which is a possibility if you have the handle adjustment screw and lock nut threaded way in. that can also cuase hard lever. cuz a little pressure causes the piston seal to block that port, by design.
 
Yes if the lever is not pushing on the piston at all.
which is a possibility if you have the handle adjustment screw and lock nut threaded way in. that can also cuase hard lever. cuz a little pressure causes the piston seal to block that port, by design.
It is pushing on the piston but doesn't move as much as I think it should. And yes the handle adjustment screw are almost fully in
 
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