Author Topic: Brakes Help Please (Read 2219 times)

Valzdl650 · « **Reply #20 on:** January 18, 2024, 08:20:38 »

Hello thanks again for the reply’s so I have been doing the process of pumping, holding in, release nipple, close nipple, release brake , pump for over an hour yesterday, both calipers have fluid passing threw the lines and out of the realease valve however the pistons are still pushed all the way in to the bores, they haven’t popped out , so althoubthe fluid is coming out of the bleeder valve it’s not pushing out the pistons ? Thanks gert, I will for sure use the syringe method when I’m next doing it as I’m sure that saves alot of time, I think I’m probably going to take the calipers back off maybe compressed air to push out the pistons slightly and then see if that helps??

Valzdl650 · « **Reply #21 on:** January 18, 2024, 08:23:51 »

The link did not load Gert but I think I know what you mean , the little silver tab inside the master cylinder , no I have done before when I cleaned the brake assembly and master cylinder but this time no I just flushed the fluid straight threw the release valves and took off the calipers

Valzdl650 · « **Reply #22 on:** January 18, 2024, 08:45:19 »

https://youtube.com/shorts/ZadIiYj9kms?si=gI3txiXlGUnO5E7G
A small video of the problem

Valzdl650 · « **Reply #23 on:** January 18, 2024, 09:06:25 »

https://youtube.com/shorts/_4LAk92WaR8?si=Z5xMw3Coe0Eqoywp
And one of the calipers, now I will flush the fluid and take them off and go from there . Any suggestions ?

Valzdl650 · « **Reply #24 on:** January 18, 2024, 17:30:20 »

Sorry blokes to spam this page but I’m now out of answers , I striped the calipers back down , compressed air to push out the pistons check everything in there was fine which it was and rebuilt them and put them back on , exactly the same pumping , got fluid to pass threw both bleeder valves but the pistons aren’t moving , I’m thinking maybe there is a issue on the master cylinder ?

nigel s · « **Reply #25 on:** January 18, 2024, 18:10:52 »

Hello Valzbl650,
Could be the master cylinder,but if you didn't mess with it and it was working before you started...........?
Don't take this wrong ,but there comes a time when taking it to a pro is the best way.
All the best.

Valzdl650 · « **Reply #26 on:** January 18, 2024, 20:09:00 »

So the bike was fully working order , removed the calipers, and now there’s an issue, at the moment I’m just fault finding , the pads are brand new calipers are all good , I stripped and fired some compressed air through and the pistons popped straight out so I know there’s no problem with them also I losened the banjo bolt when I just took the calipers off and I pumped the brake and the fluid squirted out , so really just can’t figure it out , yes last option would be to do that , but I don’t think I’m at that stage yet, I think before that I will have to have stripped down and checked the lines and master cylinder , for something like this I don’t actually think I could take it to a garage

because the fault is somewhere in either the brake lever, master cylinder, lines , calipers… it’s just a matter of pain staking going threw everything with a fine tooth comb 😫😫😫

UK_Vstrom650 · « **Reply #27 on:** January 18, 2024, 21:50:37 »

Did you put the copper o-rings on either side of the banjo between the bolt and the brake caliper (three on the throttle side if you have two lines there). Asking as I couldn't see them in your video albeit it's hard to tell, but they're needed to make the system airtight.
If you have, I can only think of torquing everything to spec and trying again.

Valzdl650 · « **Reply #28 on:** January 18, 2024, 22:04:14 »

Hello thanks mate , yes in the banjo bolt there is a washer either side of the brake line, yes completely air tight , seals in piston are good no leakage, bleeder valve airtight no leakage 😭

nigel s · « **Reply #29 on:** January 19, 2024, 05:01:56 »

If it is all okay,technique is the problem.

Gert · « **Reply #30 on:** January 19, 2024, 06:38:42 »

As to the reason for the link not working, it is the site's spelling check at work.... if one changes the capital letters of "Suzuki" and of "dl" to lower case in your browser address line, the link should work.

Valzdl650, I have read your PM, but will put my thoughts in this thread so if I overlook anything the other members can help point them out.
To me, there is air in the system. Just to clarify, did you replace the caliper seals? If I recall, the K7 Wee caiiper piston diameter is slightly smaller to that of the K4 - K6 Wee. So I was thinking that perhaps the incorrect seals where supplied...
K5 650 part number: SEAL SET, PISTON 59300-33841
K7 650 part number: SEAL SET, PISTON 59100-04851

Valzdl650 · « **Reply #31 on:** January 19, 2024, 07:47:24 »

Hello Gert, thanks for the reply , no I took everything apart and althoubit says best practise is to replace rubbers and seals I didn’t , however they are all in good order no damage to the rubber boots and the seals also have no damage

Valzdl650 · « **Reply #32 on:** January 19, 2024, 07:51:57 »

With the brake bleeding I have been doing it the same way, as I now think maybe there could be an issue with the master cylinder the times before when I bled them I remember when I would pull the leaver there would be a lot of suction in the Mcylinder but there is only a few bubbles it doesn’t suck or spit when I’m pumping the lever

Valzdl650 · « **Reply #33 on:** January 19, 2024, 10:27:35 »

Now after everything I have been trying and eliminating I think my problem is up the top, so I think the issue is with the master cylinder , the brake calipers are sweet when I put the compressed air threw they work how they should the lines are braided and there I don’t think is a problem I think the issue is in the master cylinder my front brake has always been a bit spongey and I have bleed a few times and never could get it to be stiff , but it worked , now the issue is it’s not got any suction so this is the next atep

purplebikeunicorn · « **Reply #34 on:** January 19, 2024, 17:21:13 »

If you disconnect the line from the brake caliper, and pull the lever, do you get fluid out? Have you twisted/crimped down on any of the rubber brake lines? Are they the originals?

From experience with an older bike, I had to turn the handlebars to get the banjo to be the top most point of the caliper, and the previous bike to that I had to take off the caliper entirely, put a piece of wood between the pads so they didn't pop out and bled it like that. Stubborn stubborn air!

Valzdl650 · « **Reply #35 on:** January 19, 2024, 21:27:38 »

Yes!!!!!! Finally !!!! Mannnnn

So I stripped the master cylinder cleaned it everything looked OK no signs of anything out of the ordinary put it back on and then started the process again and straight I felt the lever starting to stiffen !! So now I have brakes so I don’t know what was stopping it but now 3 days and about 10000 pumps later I have brakes!!!

Valzdl650 · « **Reply #36 on:** January 19, 2024, 21:28:35 »

Thanks for the information with the turning of the handle bars I was actually turning side to side and pumping also !!

UK_Vstrom650 · « **Reply #37 on:** January 19, 2024, 22:42:01 »

Glad you got sorted in the end

Take it steady to the pads bed in the happy riding

Valzdl650 · « **Reply #38 on:** January 19, 2024, 23:36:17 »

Yes thanks !! Yh the snow on the ground where I am so taking advantage and just giving the bike a little tlc I think tomorro night I’ll get the fuel pump out and cleaned and a new filter put on

nigel s · « **Reply #39 on:** January 20, 2024, 05:14:37 »

Result........doesn't matter how you got there ,just the fact you did.