Brakes problem

Flukester · 7 Mar 2011 at 07:58

Got a major problem with the ZX10 brakes, and cant crack it.

The ZX10 has well known spongy brakes but over the last few months the lever became really solid, and braking performance became rubbish.

I stripped down at the weekend and as I suspected 4 out of 8 pads had welded themselves to the caliper bodys with crud from winter riding.

I cleaned it all up, freed up all the pistons by pumping them one by one (and lost a few dust deals in the process DOH)

After putting all back together the lever now comes right back to bar, with braking only starting in the last inch of travel. I bled through the system with new DOT4 using a one way valve bleeder, then clamped the lever overnight.... still nothing.

Any ideas ?, I don't think it's the lines or the master cylinder as with seized pads / pistons the lever was rock hard.

Maybe some air is somewhere still in there or the one way valve bleeder thing is duff and I need to try the manual method.

Arghhhhh

Flukester · 7 Mar 2011 at 11:17

Cheers, well tried again, this time took out bleed nipples fully out and wound PTFE round them... still no change. Looking like MC has craped out on me

Flukester · 8 Mar 2011 at 06:37

Thanks for all the tips...

I must admit I jumbled up the pads, each caliper has 4 (grrr kawasaki) and they may not of gone back in the same position.

I was getting so *&^%$ off with it yesterday I whipped the calipers off one by one and decided to push the pistons back then bleed, I assumed the pistons wouldn't move with the bleeder open, but wasn't looking and popped a piston out, what a dumbass!. I think I now have a possible seal gone

Have done so much bleeding now getting kinda sick with it, I think I might book her in for new pads, new seal kit and a proper bleed from someone who knows what they are doing.

Flukester · 8 Mar 2011 at 07:03

update...

done as you said famas and after the overnight clamp just bledd MC and tons of tiny bubbles, suddenly I have some resistance on the lever. will rinse and repeat I think. the bike gets almost no hard use these days as don't have time, but things are looking promising.. hopefully my jumbled pads will bed in and things will get better.

seems the seal on piston I popped is ok... it wasn't brake fluid, my fork seal has decided to let go instead, happy days.

Flukester · 8 Mar 2011 at 07:40

it's crazy they can't come up with better ways of doing this stuff... like fitting easy bleed nipples as stock, would help a bunch, still.. that would add like £3.50 to the cost of a new bike grrrrrrrrrr

Flukester · 24 Mar 2011 at 12:29

Just a update on this, given up

The brakes are just hopeless... bad design tokico calipers coupled with OEM lines and worn pads.

Just picked up some Nissin ZX1400 calipers off ebay for £100, Goodridge lines £55, and new EBC HH pads £64.

Will post up a little photo log of fitting them once in, fingers crossed master cylinder ok.

Flukester · 28 Mar 2011 at 14:00

Nissins arrived from the 06 ZZR1400, in really nice nick with no corrosion on pistons.

Goodrich all fitted and new pads... brakes now super tight how they should be.

ps: brake fluid on tyre is coz I'm super talented and makes cornering more interesting lol