Weird KTM/Brembo brake issue

mxpatriot
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5
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12/15/2019
Location
Colorado Springs, CO, USA
mxpatriot
Been chasing a front brake issue on a '16 KTM 250sxf. Have bled the snot out of it using every method possible (vacuum, caliper elevated above master cylinder, back bleed, field bleed, etc.) and can't get a firm/functional brake lever.

However, if I have the caliper removed from the bike and allow the pads to come together, I have a very firm brake. If I shove a screw driver or other rotor size spacer in between the pads, I go back to having a soft/unsafe brake lever.

I've rebuilt the master cylinder and have replaced the brake line.

Thoughts on next step on this?
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Factor E
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9/22/2011
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So Cal, CA, USA
Factor E 9/25/2020 8:22pm
9/25/2020 8:22pm
Crack bandjo fittings open while applying pressure with lever
top to bottom
mwssquad827
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8/4/2016
Location
Twin Falls, ID, USA
mwssquad827 9/26/2020 7:57pm
9/26/2020 7:57pm
Factor E wrote:
Crack bandjo fittings open while applying pressure with lever
top to bottom
Yes bleed them at the banjo bolt... this was the issue for my 17 tc front brake...
captmoto
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4/22/2009
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Rancho Cucamonga, CA, USA
captmoto 9/27/2020 10:14am
9/27/2020 10:14am
When did tis problem start?
Does it have aftermarket levers? If so, swap out to a stock lever and try bleeding again.

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