Can't flush any fluid through rear brake line? Help! - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 37 Old 08-31-2017, 04:35 PM Thread Starter
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Can't flush any fluid through rear brake line? Help!

Hi one and all -

Recently bought a 2000 650c, and need to do a bunch of work on it to get it roadworthy. I did the fork seals yesterday, today wanted to get the rear brake working. There was no brake feel whatsoever so my first step was to bleed the system. Attached some hose onto the bleed valve, pumped the pedal, held it down, cracked the valve and closed it again.

Repeat for over an hour...

About an inch of very dark (almost black) fluid came into the hose, that's it. Figured there was a blockage somewhere - unscrewed the bleed valve completely, pumped the pedal - nothing. No fluid came out at all.

Then tried loosening the banjo bolt on the caliper - no fluid came out of that, or the caliper.

Removed the brake line completely, tried blowing some air down there and it seems to be ok, unblocked.

I have no idea what to try next. Pumping the brake pedal has no effect at all, and whatever fluid is in the system is black as the ace of spades.

Any help would be very gratefully received!

Thanks,

- J
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post #2 of 37 Old 08-31-2017, 05:28 PM
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Probably want to rebuild the Rear Brake Master Cylinder, at the least.

Rebuilding the Rear Caliper might not be such a bad idea either; even if you can bleed the system after rebuilding the Master Cylinder.
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post #3 of 37 Old 08-31-2017, 05:54 PM Thread Starter
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Ok, this'll sound like amateur hour but man that's how I roll...

The master cylinder, that's the metal cylinder, bolted vertically onto the frame?

Be gentle...
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post #4 of 37 Old 08-31-2017, 06:54 PM
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That's it, yes.

New, we Merkuns don't know nuttin' about you Canadanians and your 650Cs, but I'm going to go out on limb and say that the C has the same master cylinder as the A.

What you need looks like this: https://www.amazon.com/1987-2005-Kaw.../dp/B005PHCLL4

Is the front brake OK? You might figure it is in need of some help, too.

Not to be a Gloomy Gus but, if the master cylinder is all gunked up, the calipers are probably in need of a cleaning and perhaps a rebuild, too. I'd at least pop the pistons our and clean everything real good.

Tom [email protected]

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post #5 of 37 Old 08-31-2017, 07:36 PM Thread Starter
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Oooh, that might suck - here I am with my fancy but beaten up 650c and y'all don't got them south of the border. There could be trouble ahead...

So you guys never got the C model in The States? It's a snazzy little number - different front fairings, smaller, leaner tank, me I love the look of the thing. Crusty she may be, but there's gold in them hills...

Thanks for the info on the master cylinder Tom, I really appreciate it. I have a little experience now after building my '81 Honda CB750, and am no stranger to asking questions on forums either - just ask the very patient folk over at dotheton. Man they got some questions from me alright, barely knew a carburetor from a clutch plate when I started that build. So taking the caliper apart shouldn't be too much of a problem but I do like me a good video - I'll see if I can find something on youtube to walk me thru it. The master cylinder however is virgin territory. Thanks for the link, I'll take the thing apart tomorrow and report back on the state of play.

One thing - popping the pistons out. Doable with some fluid/hydraulic pressure in the lines, but without it? I don't have an air compressor - trip to my local shop and ask them to do the honours?

Good man, thanks fella
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post #6 of 37 Old 08-31-2017, 08:39 PM
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WOW! Brain fart! I was just over on the Versys 1000 forum before I jumped over here and read this post. I almost posted that it might have something to do with the ABS but I caught myself just before I looked foolish

“Take the risk of thinking for yourself , much more happiness , truth, beauty, and wisdom will come to you that way.” Hitchens
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post #7 of 37 Old 08-31-2017, 10:52 PM
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Quote:
Originally Posted by TheJimbonaut View Post

One thing - popping the pistons out. Doable with some fluid/hydraulic pressure in the lines, but without it? I don't have an air compressor - trip to my local shop and ask them to do the honours?
If you are gonna have the front brake apart to service it anyway, you can just use the front master cylinder to pop the pistons out. Or, they will pop out once you get the rear master sorted out.

If any part of the brake system is suspect, it's highly likely all of it is. I'd be tempted to tear down both systems and show them some love. Relatively easy and cheap work...and it is your brakes after all.
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post #8 of 37 Old 09-26-2017, 05:55 PM Thread Starter
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Finally (after a couple of false starts and wrong parts) received the rebuild kit for the rear master cylinder - assembled the thing but still no dice.

I have no idea what the problem is - with the cylinder bolted onto the frame, the brake pedal attached and the reservoir connected to the cylinder (but without the line to the caliper connected) there is no fluid coming out of the top of the cylinder when I pump the brake pedal. Nothing at all. Is there something I can check? If no fluid is moving through the cylinder then none would move through the brake line to the caliper, correct? Really want to get this thing fixed!

Any help would be amazing, thanks guys
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post #9 of 37 Old 09-26-2017, 06:52 PM
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Is there something obstructing the low from the reservoir into the master cylinder?

Perhaps there gunk in the bottom of the reservoir, in the hose, or in the banjo bolt.

Do you have firm pedal or does it move with no resistance?

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #10 of 37 Old 09-26-2017, 07:40 PM Thread Starter
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Quote:
Originally Posted by Tom Schmitz View Post
Is there something obstructing the low from the reservoir into the master cylinder?

Perhaps there gunk in the bottom of the reservoir, in the hose, or in the banjo bolt.

Do you have firm pedal or does it move with no resistance?
Nothing obstructing anything (I totally cleaned the whole master cylinder and hoses etc)
No gunk anywhere (and the banjo bolt is not connected at this time, just the reservoir to the MC)
Firm pedal I guess, no resistance

??
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