2006 XZ-6R - Struggling to refill brake fluid - KawiForums - Kawasaki Motorcycle Forums
 
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post #1 of 3 (permalink) Old Today, 05:45 PM Thread Starter
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2006 XZ-6R - Struggling to refill brake fluid

I replaced my brake lines with steel braided lines and rebuilt the master cylinder. I'm still working on the front brakes. I am now refilling the brake lines but I cannot get the brake fluid to flow through the lines.

There is plenty of suction with my hand pump. I can pump it to 500 mmHg and it'll hold steady. At best a small amount of fluid streams out but never a full tube. If I pull on the brake lever it squirts some fluid into the tube. I've left a vacuum on the line and repeatedly pumped the lever for the past few hours with no luck.

I'm about ready to take it to a shop but if anyone has any suggestions I would appreciate the insight.

2006 Kawasaki Ninja 636cc
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post #2 of 3 (permalink) Old Today, 07:02 PM Thread Starter
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Well I opened the nipples more than I had before and to my surprise the front nipples both eventually pumped until there were no bubbles. However, the master cylinder nipple now continuously pulls bubbles. This is what happened before I rebuilt the master cylinder and was why I chose to do so. Does this mean I have a leak somewhere?

2006 Kawasaki Ninja 636cc
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post #3 of 3 (permalink) Old Today, 10:47 PM Thread Starter
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Problem solved. It was mostly my having very little clue what I was doing. The master cylinder nipple was not sealing around my pump so the continuous bubbles were just that. The air was mostly pumped out already. Without the pump I squeezed the lever just before brake fluid came out and tightened it. That did the trick and the brakes work perfect. The rear line took 20 minutes. Now the real test will be to see if the brakes remain stiff and do not become spongy. (The old lines were this way)

2006 Kawasaki Ninja 636cc
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