Posts
126
Joined
8/2/2018
Location
Chandler, TX
US
So I crashed hard last weekend, got up and my front brake was locked. Upon inspection I found the dust cover was wrapped up in the lever causing the lock up. After that though on the way back to the truck it would work at full power if you pumped it a few times.
Got home and figured it had air in the line. Bleed it and bleed it and never got anything but half power at best. I put new copper washers on, replaced the master cylinder plunger and seals with an old set I had. Still half power. I took apart the caliper and checked everything. Still half power.
When I pull the lever all the way into the grip the brake works. The wheel is locked but no way is the system working correctly. I am at a loss. I order new seals, and a new line thinking there might be an issue there? I would love to hear some input and your thoughts. Thank you......
Got home and figured it had air in the line. Bleed it and bleed it and never got anything but half power at best. I put new copper washers on, replaced the master cylinder plunger and seals with an old set I had. Still half power. I took apart the caliper and checked everything. Still half power.
When I pull the lever all the way into the grip the brake works. The wheel is locked but no way is the system working correctly. I am at a loss. I order new seals, and a new line thinking there might be an issue there? I would love to hear some input and your thoughts. Thank you......
Paw Paw
The Shop
My buddy brought his KTM over and we started swapping parts. First the slider pin. Same result. I replaced the caliper mount arm and same result. Swapped the whole system from his to mine and everything worked perfect. So that means the fork bracket isn't bent.
After all said and done it appears the caliper mount for the brake pin is bent outward. How in the heck can this happen? No marks of damage or stress. I can't see this bending without breaking but it's the only thing it can be.... Any thoughts?
Losen the banjo bolt at the canister and rotate the brake line down so you have a falling line. Also turn the brake reservoir slightly upwards. Turn the handlebars to the left and flip with the brake lever for a minute or so while knocking gently at the brake line around fork protector height. Then turn bars the other direction and it should come some air out that gets stuck passed the bleed holes in reservoir.
I have had major issues with ktm mushy front brakes. Filling them backwards with a big syringe did not help and neither did putting complete caliper in brake fluid.
The above works every time I do it.
So here's the verdict. The cerakoted caliper is the old one. The silver one is a new one. If you look closely you can see the brake slide pin is pointed upwards on the old one. It turns out it's 3 mm taller at the end. I've changed the slide pins and it's still 3 mm taller. Somehow that caliper got bent. For the life of me I have no clue how this could possibly happen without damaging other things along the way. What a frustrating journey. But I got it all figured out. I ended up finding a new caliper on eBay with the pads which are brand new shipped to my door for $100.
I appreciate everybody's input on this and hopefully it never happens to you guys.
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