I had a front brake line explode on me a while back. So I looked around and found a line off a KTM SX for $10. It is a little shorter than the stocker. After back bleading twice, it still is super spongy and takes a bit to bite. The braking power is pretty weak. It won't lock up if I try. I'll go around and test other bikes front brake and they have that initial braking power needed. What could be going on? I pushed the caliper in, fed a bunch of fresh fluid up to the resv. with no bubbling. I don't like the way it feels. Could have to do with the brake line itself? The type of fluid used (Prestone Synthetic DOT4)? What about the brake components?
YES It could have a soft spot in it somewhere or it just could be worn out in general. If it's so bad that you can't lock up the brake I'd say it is most certainly the brake line as I've had a similar experience. Any local hydraulics shop can make a brake line for your bike while you wait. Just take the old line in and they'll match up the fittings. Get a steel braided line and get the exact stock length (unless you have bar risers or similar)
The thing is, I can't remember if the brake was that great to begin with. Could it be the master cylinder? I've heard switching to a Nissin fixes this. If there was an air leak, wouldn't fluid eventually find its way out that hole. I haven't found anything.
It wouldn't be an air leak, it would be that the hose has lost it's strength. So, when you put pressure on the lever the hose expands just the tinyest amount. I don't think it would be the master cylinder. In my experience the master cylinder either works or doesn't, no middle ground. If you have decent pads and fresh fluid of any kind...even if it isn't what is spec'd, it should work. Maybe look the brake line over and see if there are any worn spots or kinks in it.
if the m/c has a split or tear on the piston seal the lever 'll go to the bar and pressure will bleed off. line could be sacked, most wear out over time. first- remove caliper, get all loops out of line, make the m/c the highest point and let the air find it's way up to the resv. tapping the line with a small screwdriver helps get little bubbles out and on the way up. warmer temps help too. if its freezing in your garage take the system inside where it's warm as that'll warm the fluid etc. if yer positive there is zero air in system and fluid is not mixed or contaminated try another hose. also- take the entire system apart and clean it with the fluid you intend to use before hose change. some m/c's make diff pressure than others and this with an aged/wrong/contaminated hose can cause issues. recent husky's have about the best brakes i've come accross. the sets on my current TC and WR are incredible strong and 110% abuse proof. i suggest getting the system back to as OE. and let us know what you find!
So you think it's the line. I guess it would make sense. I have a plan. I am changing the mc to a nissin and going from there. I have read that should fix this issue. If not, it only cost me $29 for the mc. Then if it doesn't work. I'll put the mc back on eBay, go to a hydro line place and have them build me a new brake line. The cost of an OEM one is stupid and I won't pay it. The mc should be here maybe end of this coming week, depending on shipping. Then I'll report back. I had already been into the line building shop. I had them attempt to fix the original broken line. They didn't charge me any money since they didn't think it would hold (liability) due to the small diameter of the hole. Good thing too. It leaked instantly. With that honesty though, they will get my return business with full intent to pay.
So I decided to buy a Nissin master cylinder. I was sure it wasn't the brake line since it's a braided steel line. I went on ebay. Started looking around and found a '97 Honda CR125 master cylinder for $22! I then cross referenced new Honda's and found that the one I could buy, is the same as newer models! Done Deal. It arrived quickly and was installed last night. Got it all back together and vwalla, BRAKES! Good brakes! It grabs the way it should. I will be able to stop now.
After getting back on a 2t, I feel that my speed has increased. But dealing with this brake issue has slowed me down. Pretty scary not slowing down when you need to. So yes, I do need to be careful now.
Go into the turn harder,brake later & gas it out! It's a very scary feeling w/o a brake! Or being tapped out in 4th & going from a field into a tree ladened single track with your buddies behind you! No brakes! WATCH OUT! Single most important componet on our motorcycles. At least for safety. I'm glad yours are fixed.
Howdy, Only have new KTM's with Brembos, but had this same issue and a very tiny amount of air was trapped in a small cavity inside the brake unit at the wheel. This caused the front brake to feel spongy even after replacing with new lines. But since you remidied this way great! My 1981 430CR Husky's front brake does not stop well either and I have replaced the cable, but they all seem too short and there is never enough adjustment! Must be the brake shoes!
