1. 2 Stroke Husqvarna Motorcycles Made In Italy - About 1989 to 2014
    WR = 2st Enduro & CR = 2st Cross

125-200cc WR 125 Front Brake Problem

Discussion in '2 Stroke' started by Tentontimmy, Jul 6, 2014.

  1. Tentontimmy Husqvarna
    AA Class

    Location:
    Caribbean
    Husqvarna Motorcycle:
    2012 WR125
    Other Motorcycles:
    Suzuki GSX-R1000
    Hi guys, looking for some help with my front brake. Went for a ride today and on a long descent the front brake overheated and went spongy. I waited for it to cool but now the front brake lever is solid and won't compress at all.

    It's not holding the brakes on - the front wheel spins freely and the pads aren't dragging on the disc.

    I have tried bleeding the brakes at the caliper. After pulling some initial fluid through, no more fluid is coming through.

    I also tried squeezing the lever whilst the caliper bleed nipple was cracked open - nothing, won't compress at all.

    Feels like there could be a problem with the master cylinder or a blockage between the master cylinder and the caliper. Does anyone have any suggestions?
  2. Tentontimmy Husqvarna
    AA Class

    Location:
    Caribbean
    Husqvarna Motorcycle:
    2012 WR125
    Other Motorcycles:
    Suzuki GSX-R1000
    Update: Disconnected the brake line at the master cylinder. The lever moved freely. I reconnected the brake line and pumped the lever. Pressure built up until the lever was rock hard again. Still no action on the caliper though.

    So I disconnected the brake line at the caliper. The lever was still solid and no fluid flowed out of the line no matter how hard I squeezed.

    So the blockage is in the brake line. I think I read somewhere about dirty fluid near the caliper being forced up into the brake line when the brakes overheat.

    What's the fix? If I keep squeezing the lever can I force the dirty brake fluid out the end of the line? Don't want to damage my master cylinder though.
  3. Chef Husqvarna
    AA Class

    Location:
    Ontario, Canada
    Husqvarna Motorcycle:
    08 Cr165, 09 Wr165
    Other Motorcycles:
    01 Husaberg FE650, 07 BMW 650 Dakar
    Why not disconnect both ends and blow it out with air?
  4. Tentontimmy Husqvarna
    AA Class

    Location:
    Caribbean
    Husqvarna Motorcycle:
    2012 WR125
    Other Motorcycles:
    Suzuki GSX-R1000
    Thanks. Will give it a go. If I can't clear it somehow I think the best way forward is a new brake line
  5. Tentontimmy Husqvarna
    AA Class

    Location:
    Caribbean
    Husqvarna Motorcycle:
    2012 WR125
    Other Motorcycles:
    Suzuki GSX-R1000
    Found a new line for a 2012 WR 250. Anyone know if it will also fit the 2012 WR 125?
  6. Dirtdame Administrator

    Location:
    Rock Springs Wy
    Husqvarna Motorcycle:
    11 WR300,13 WR125,18 FE501
    Other Motorcycles:
    17 Beta Xtrainer
    Before you put a new brake line on, you ought to make sure that the caliper piston isn't the culprit. If you undo the brake line from the master cylinder and then compress the piston on the caliper, does it move. Then try compressing it with the brake line removed from the caliper.
  7. Xcuvator Husqvarna
    Pro Class

    Location:
    Scholls Oregon
    Husqvarna Motorcycle:
    TE450,610 WB165,WR250 WR360 & XC430
    Other Motorcycles:
    yes
    Sometimes a brake line-liner will separate due to age, injury or both and collapse causing a partial or complete blockage.
  8. shawbagga Husqvarna
    Pro Class

    Location:
    Eaton, Western Australia
    Husqvarna Motorcycle:
    None
    Other Motorcycles:
    2018 Gasgas XC250
    125 & 250/300 seem like theyre the same but don't quote me
  9. rabskyline Husqvarna
    AA Class

    Location:
    Sunshine Coast,Queenslander !!
    Husqvarna Motorcycle:
    2014 te250r
    Other Motorcycles:
    Yer maw !
    Would more likely be a stuck caliper or related , don't reckon it's a line.
  10. Tentontimmy Husqvarna
    AA Class

    Location:
    Caribbean
    Husqvarna Motorcycle:
    2012 WR125
    Other Motorcycles:
    Suzuki GSX-R1000
    Thanks for the replies everyone.

    I did some more investigating last night. Took a spool of lockwire I had lying around and carefully fed the wire into the brake line starting from the master cylinder end. It went in almost to the other end and then stopped. Wouldn't go any further.

    So I tried feeding the wire in from the caliper end of the brake line instead. Immediately found the problem. The caliper end of the brake line was completely blocked up. Took a lot of effort but I was finally able to force the wire through the blockage and up into the brake line.

    Sprayed some brake cleaner on the wire and ran it in and out of the line until it was moving freely. I will try flushing the line through but I am worried that there may still be remnants of the blockage in the line that could give me another problem. So will put a new line on to be safe.

    I would really like to understand exactly what caused the blockage. As I mentioned the brakes overheated and the lever came back to the bar (even though I am careful about changing my brake fluid regularly to keep it fresh). It almost looked like the end of the line was fused closed. :excuseme: