Working on 86 Voyager XII. Bike had been setting for a couple years and the brakes sucked, so I dug in to replace and repair eitire system. After removing front master cylinder, cleaining out the gunk and sluge I installed all new seals and piston spring with seals. Did the same thing to both front calipers. After 3 hours of bleeding air out of the system I still have a lousy brake handle. Feel very mushy, and when I squeeze the handle i get resistance but only have about 3/4" between handle and throttle grip. I tried to isolate my problem by applying a hose clamp on the individual brake lines. When I clamp the line from the master cylinder I get a very firm handle and can only squeeze it about 3/8". When I clamp off either caliper line I still get a soft handle. What I see it the caliper pistons are extending when the brake handle is squeezed but retract back into the caliper too much when the brake handle is released.

Please help, this is the only thing keeping me from getting this bike on the road. I have been working on this machine for the last 6 months and the project is almost complete, but this problem is kicking my butt. Any sugestions would be greatly appreciated.

 

is there any kind of brake lever adjustment? if you were bleeding air for 3 hrs, then you've got a leak somewhere

 

Yep, maybe brake lever adjustment. Maybe your rubber lines are swelling when you apply brake? Old lines maybe? You did use DOT4 fluid right?

 

Thanks for the reply guy's. First I did find a small seep at a banjo bolt sealing washer, and I'll replace that tonight and try again. I did use DOT 4 fluid. I'll see what that replacement washer does and let you know. Just seems wierd how much the caliper pistons move back into the caliper when the lever is released. It has no adjustments to mess with either. I'll post tonight what I come up with. Again thanks.

 

This thing is kicking my a__ __. I am now getting a nother set of calipers and different complete system. Thanks to some help from So CAL Voyazgers, this thiing may fly yet. Keeping my fingers crossed.

 

Hopefully that will fix it up.... Have you checked the Master? Maybe fluid is bypassing the piston?? Take the hose off and plug it, and then see if you have the same lever feeling.... Just an idea..

 

Most likely is the junction block (where line from master cylinder goes into and then splits to go to each caliper) which is mounted on the lower triple tree has air stuck in it. Sometimes tapping it will help. That's why when you clamped off the upper line you had good feel. That is before the junction block. Clamping off in front of the calipers is after the junction block and will feel spongy if there is air in the block