Question about 2002 KTM LC8 950 Rally

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Rear brake cylinder and bleeding

On my KTM 525 2004 model I have just replaced the rear master cylinder. Upon trying to bleed the brakes again no pressure comes through the lines. I have removed the lines and pressure tested them and there seems to be no obvious leaks. Upon taking of the brake cylinder and filling both sides (reservoir and cylinder side) with brake fluid but having no lines attached upon pushing the master cylinder in liquid comes out but if this liquid is removed it is not replaced from the reservoir. Thus it only expels from the master cylinder that which is already in it and doesn't replenish itself from the reservoir. What is going wrong here?

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Relax....KTM's are delicate in this procedure.
First of all make sure that you are using DOT 5.1 brake fluid and not 4 as we use in the Japan models.
Then take the rear caliper in your hands and push the piston all the way in.Then bolt it on its position.
Bolt on the brake hose to the rear caliper tight and leave it loose on the rear master cylinder side (loose but ready to tight it on like half circle loose) and clean up the reservoir completely.
Take a syringe from a pharmacy and a piece of 3mm clear tube.
Start pushing brake fluid in the caliper's loose bleeder until you see fluid coming out fron the hose's loose end on the master cylinder.
The tight the cylinder's bolt and keep pushing fluid until you see it filling up the reservoir.
When you see the reservoir fully filled up, tight the bleeder, take out the syringe and start pressing the brake pedal 15-20 times and the last one keep it down and loose the bleeder (with a tube attached to it and to a bottle) for a sec to relieve the pressure along with any air bubbles.DON'T LIFT THE PEDAL UNTIL YOU HAVE TIGHT BACK THE BLEEDER or the system will **** air in.FIRST tight the bleeder and THEN loose the pedal.
Keep doing that until NO air comes out of the system.
While you are doing this second stage keep filling up the reservoir and do not let the master cylinder **** air in.

Posted on Jun 15, 2009

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Posted on Jan 02, 2017

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How To: Bleed Your Brakes - Feature - Car and Driver

www.caranddriver.com > Features

Car and DriverIf there is a substantial fluid eruption, there are air bubbles still trapped in the system. You must repeat the bleeding procedure to remove that air. A modest disturbance in the fluid returning to the reservoir indicates a properly bled brake system.

How to Bleed Brakes - Tips on Bleeding Brakes

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