Kawasaki ZX6-R (G2) Front Brake Problem

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Kawasaki ZX6-R (G2) Front Brake Problem

Hi All

I have a major problem with the front brakes on my ZX6R (G2 - 2000 model)

A bit of background:

I use my trusty W Reg (2000 model) ZX6 day in day out, commuting to and from work. Over the years, time has taken its toll on my front brakes.

It ended up my front pads had locked solid to the disk. I'm not at all mechanically minded, but my mate, Kevin, who is a dispatcher, is.

He took both callipers off, cleaned the pistons and replaced ALL the seals. Lovely. Except the lever came right back to the bars. The brakes worked, after a fashion, but I didn't trust them to stop me in an emergency.

He thought the only thing it could be was the master cylinder kit. So the complete thing has been replaced. The result? The lever STILL comes back to the bars.

Kevin has spent ages bleeding the brakes. He even spoke to my local Kawasaki dealer, Grays Motorcycles, in Essex, where I bought the bike. They suggested back bleeding, which he did, to no avail.

Kevin says there are no bubbles coming out at all, but the lever still comes back to the bar.

If it makes any difference, I had braided hoses put on a couple of years ago. When the guy was fitting them, it took ages and ages to bleed them. To be honest, I haven't really noticed any significant difference between braided and original. It just seemed 'the thing to do' at the time.

The only thing we can think of is the hoses themselves. But, it's an expensive 'test' to fit another set of braided @ approx £80 or original Kawasaki's @ £150-.

Any ideas what I could try next, or where I could find a brake specialist in the SE London/Lakeside, Essex/Bluewater, Kent area?

Tks

When there's too much 'give' in the lever, you've either got bubbles in the system, or you're losing fluid (as you've replaced the master cylinder). If you do a lot of squeezes right back to the bar, then if there's a leak somewhere, you will notice the fluid leaking from somewhere and you will see the fluid level reduce. If it's not a leak of fluid, then you've got bubbles in it. Just because you've bled it and it's no better doesn't mean it's not bubbles, it just means you haven't got them out yet - eg. on my car, in order to bleed the rear brakes properly, you have to take the caliper off the disk and turn it upside down.Maybe it's something to do with the arrangement of the hoses - what arrangement do you have - does the hose go from lever to 1 caliper and then that caliper feeds the other one, or do you have 2 hoses coming down from the lever. If you have one caliper feeding the other, maybe you've got air trapped in the top bit of the arch which bleeding won't shift - perhaps try removing the 'slave' caliper from the fork and holding it above the 'arch' while you bleed it (Don't forget to stick something in the caliper so the pistons don't pop out).

Thanks for the reply. I think I have 2 seperate hoses coming off the lever, dropping down to both calipers. I'd have to check when I get home to be sure. But, from what I remember, it's 2 straight from the lever.I'll have a check tonight and post again here tomorrow.

johnholt_zx6 wrote

Thanks for the reply. I think I have 2 seperate hoses coming off the lever, dropping down to both calipers. I'd have to check when I get home to be sure. But, from what I remember, it's 2 straight from the lever.I'll have a check tonight and post again here tomorrow.

Go to any motor factors and get the one way bleed valve for cars, it fits on bike nipples. And a large tall jar and start bleeding. They will not allow any air to get in to the system, and is one man operation. Just bleed as normal and make sure reservoir fluid level always above feed to pipes. You also only need to loosen bleed nipple maybe 1/4 turn, do not slacken anymore than needed! Even though it is one way valve always have lever fully depressed while tightening nipple after bleed for good measure. They are inexpensive and in my opinion the best way.

If all else fails, empty the brake system of fluid completely by pumping the lever, then get a big syringe and fill it with fluid. Open the nipple(s) and blow the fluid in from the bottom. This pushes the air in front of the fluid - in the direction it wants to go anyway.If you're unsure, please find a specialist; brakes are safety-critical items which could save your life.

Thanks for all your comments. Much appreciated.For YourOldNemesis - I checked last night. I definitely have 2 hoses coming down from the lever; one directly to each caliper. You gave me a tip, if one caliper was feeding the other. Do you have any other tips where the master cylinder is feeding both directly?For MorayR6 - My mate already has a one-way bleed valve. He reckons it's ok, but he said he's probably going to buy another, to be on the safe side.For redrooster - Excellent idea. My mate already mentioned that, but had no idea where we could buy a big syringe. Any ideas?

I think everyone is on the right lines (groan). To add.if you have sperate lines you can unbolt the claipers and jam som old wooden clothes peg halfs inbetween the pads. Wheel the bike up to the bench and put the caliper on the bench. Having the caiper higher help the air travel uphill to the bleed nipples, makes thing easier.Kev

Ok sounds like you may have air trapped in the brake calipers. take each one of and one at a time open the bleed nipple and force the caliper open by pushing the brake pads apart. Any air trapped in the caliper will be forced out of the nipple. You may have to do this a couple of times with each caliper. Inbetween close the nipple and pump the brake filling up with extra fluid as required.

johnholt_zx6 wrote

Thanks for all your comments. Much appreciated.For YourOldNemesis - I checked last night. I definitely have 2 hoses coming down from the lever; one directly to each caliper. You gave me a tip, if one caliper was feeding the other. Do you have any other tips where the master cylinder is feeding both directly?For MorayR6 - My mate already has a one-way bleed valve. He reckons it's ok, but he said he's probably going to buy another, to be on the safe side.For redrooster - Excellent idea. My mate already mentioned that, but had no idea where we could buy a big syringe. Any ideas?

local pharmacist or chemist is probably the best bet for a syringe.Jiz :smoke:

cant get pistons to push out tried everthing got pads out but pistons wont budge

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