Ihave a 1989 harley sportster and i cant get the brakes to bleed..ive stripped the macter cylinder,cleaned and reassebled it..everything was as it should be going by the manual but the master cylinder dos'nt seem to be doing anything..even when ive removed the pipe from the caliper and capped the ends of with my fingers..its seems to create more of a vacum than pressure..any ideas greatly appreciated as the problem is driving me nuts..cheers..rich
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Re: Cant get brakes to bleed..
Easier to do from the bottom up.... (bubbles rise...right!)
You can get a pump at an auto parts store - I made one with a syringe and a peice of tubing. Attack the tube to the nipple at the caliper. Open the resavoir and fill the pump with fluid. Force it slowly up through the calpier, let it overflow the res. When the bubbles stop, close the nipple. If dual caliper, do the bottom, then the top. Close the system and pump the brakes a few time. that should do it
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you need to take your carb off give it as good cleaning. also check your intake gaskets where the manifold joins the jugs and the black rubber one where the carb joins the manifold. You def have air/fuel problem going on. also check your vscume hose to the carb but im thinking that is not it.
Is this using stock brake lines? You could have kinked the metal tubing and possibly broke it when you straigthened it out. I would suggest getting someone to help who knows what they're doing on brakes... pretty dangerous if you make a mistake. With that said, the system *is* pretty darn simple. The master cylinder is a pump and the caliper is the actuator. If you have the reservoir filled with the correct fluid and the system has been bled properly, meaning no air in the lines, then unless it is leaking there is no reason you won't have brakes, unless the seals in the master are blown out.
If you need to start over... get a master cylinder seal kit, a caliper seal kit, and a bottle of the correct fluid from the dealer. Both kits are around $20 and since your bike is 10 years old it wouldnt hurt to replace the seals. Rebuild the master and the caliper according to the service manual instructions. Also make sure you fully inspect the brake line to make sure you didnt kink it.
Take the master cylinder off the bike and try to "bench bleed" it in a vise.Fill with fluid and put you finger over the outlet,push plger in with a screw driver.If no or very little pressure replace the master cylinder. If it does pressure up install and bleed system one section at a time.When bleeding a dry system DO NOT LET THE RESERVOIR RUN LOW or you will get air in and be there forevere bleeding.
Follow the actuating rod from the bottom of the brake pedal to the master cylinder. The switch is threaded into the inboard side of the master cylinder and is a pressure switch. If you disconnect the 2 wires and short them together, the brake light should turn on when the ignition switch is on. If it doesn't the problem is in the rear end wiring, not the switch. A couple hints if you replace the switch: Put some pipe dope on the new one and have it ready to go. Unscrew the old one and quickly apply the new one before all the brake fluid escapes. That way you won't need to bleed the brake. Also, see if they have an Accell brand switch. This one of the few aftermarket products that is better than original. Cheaper, too.
What u are describing is typical of a faulty ignition system, but could also be a fuel problem. I check by removing the aircleaner and rotating the throttle. If u see a nice spray of fuel, thats probably not the problem. Check for a spark at the plugs. I can explain how if you need me to. If you cant see a good spark, U have an electrical problem. I had a crank position sensor go bad on me. Dont do what I did (replaced the battery, ignition, and regulator as part of my diagnosis procedure)
if you have power at the harness pin but not the light then your problem could be a cut wire grounding to frame between connector and light. you did not say what kind of light you have. a regular filament light check the socket as they sometimes go bad due to vibration, if it is a led light, look for a bad componet on the circuit board like a open resistor or such. if you are handy with a soldering iron, you can repair it pretty cheaply.
very simple system my man. the brake handle connected to the master cylinder connected to the brake line connected to the calipers via the plumbing in between. so check your fluid level first if its low then top off and bleed those babies. also check the pads because as the pads wear the piston in the caliper moves further out so more room in the system so lower fluid level or you got a leak. or the master cylinder is bad. start with the obvious and dig deeper good luck and let me know tell me more about the malfunction too