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Can't Get Pressure In The Brake Lever #148331 06/27/20 12:59 AM
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Kenny4 Offline OP
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The bike is an 07 with 500 miles on it. The brake fluid I'm sure is the original. The front brake worked ok and was just a little squshy. The fluid was a dark amber so I decided to bleed out the old and replace with new. Put a 8mm box and a piece of clear hose on the bleeder screw. Pumped brake lever a few times, loosened the screw, a little fluid came into the hose and the lever came all the way to bar, held it there and tightened the screw and then released the lever. Tried to pump it for a 2nd bleed and zero pressure at the lever. So that's where I am at present, any suggestions.

I've done autos and my street bike the exact same way and have never encountered the above problem even when I had air in the lines.---Thanks

Kenny4

Re: Can't Get Pressure In The Brake Lever [Re: Kenny4] #148335 06/27/20 02:04 PM
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ppilotmike Offline
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There may be some debris blocking the inlet port of the master cylinder. Try removing all the remaining fluid in the master cylinder with an old Turkey baster or similar device so you can see the port. Yamaha basically recommends O/H the cylinder with new rubber components every 4 years.

Re: Can't Get Pressure In The Brake Lever [Re: Kenny4] #148336 06/27/20 02:45 PM
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Craig1 Offline
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You may have pulled the lever and master cylinder piston to a position it hasn't been in years. To a cruddy part of the MC, and the piston got stuck there. Confirm the piston is moving with the lever.

Re: Can't Get Pressure In The Brake Lever [Re: Kenny4] #148339 06/27/20 11:45 PM
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Selden Offline
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"The brake fluid I'm sure is the original." Ewww — 13-year old brake fluid. There are so many possibilities here. First, disassemble and clean everything, as a small piece of crud may be restricting flow. Fill with fresh brake fluid, and use a vacuum bleeder pump at the caliper end to suck out brake fluid and remove any air bubbles.

I replaced both the pads and the rubber brake line on my 2006 XT225 two days ago. Fortunately, no air in the brake line, and it works just fine.


Don't fix it if it ain't broke, don't break it if you can't fix it.
Re: Can't Get Pressure In The Brake Lever [Re: Craig1] #148340 06/28/20 12:16 AM
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Kenny4 Offline OP
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Originally Posted by Craig1
You may have pulled the lever and master cylinder piston to a position it hasn't been in years. To a cruddy part of the MC, and the piston got stuck there. Confirm the piston is moving with the lever.


Craig---That sounds about right as when I released the bleed screw the first time it slammed to the bar where I held it tightly til I closed the bleed screw. After that first bleed the lever just feels like air with zero restriction. On some MC"s you can visually see the piston at the bottom of the MC. On this bike how do you confirm that the piston is or isn't moving.

Do any of you think removing the caliper and squeezing them in would put enough pressure in the line to free things up? Or sending fluid from the bleed screw up to the MC might help. Sort of like this vid. Thanks

Reverse Bleed

Kenny4

Last edited by Kenny4; 06/28/20 01:07 AM.
Re: Can't Get Pressure In The Brake Lever [Re: Kenny4] #148341 06/28/20 04:53 PM
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Craig1 Offline
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On my 92 XT225, I can see where the free play adjustment screw pushes on the piston. As I start pulling on the lever, the free play it taken up, then the adjustment screw starts pushing the piston in. If the screw is not contacting the piston until the lever is pulled all the way in, the piston is stuck.
Yes, you may be able to pop the piston out by pushing in the caliper pistons. Even if you do get it to pop out. I would push it back in and repeat until it slides back out on its own.
If it won't come out on its own, rebuild the MC.

Re: Can't Get Pressure In The Brake Lever [Re: Kenny4] #148345 06/29/20 05:06 AM
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Kenny4 Offline OP
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Just took a look at it. The adjusting screw doesn't touch until the lever is at the bar. I will try to see if I can loosen it by compressing the calipers. Thanks for chiming in.

Kenny4

Re: Can't Get Pressure In The Brake Lever [Re: Kenny4] #148350 06/29/20 11:26 PM
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Kenny4 Offline OP
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Back to normal. Doesn't take much to screw up a simple procedure. So for those who may come to this thread with a similar problem, I'll summarize. Tried to bleed as in the first post. I gripped the brake lever too tightly while opening the bleed screw and slammed it to the bar forcing the piston in further than normal where it got stuck. The resolve was to take the caliper off and compress it to build back pressure in the line & that freed up the piston & I was able to bleed as normal with the brake working fine. Thanks again for the comments and help.

Kenny4

Re: Can't Get Pressure In The Brake Lever [Re: Kenny4] #148363 07/01/20 08:05 PM
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Selden Offline
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Congratulations, and thanks for the analysis, which may help others avoid the same problem.


Don't fix it if it ain't broke, don't break it if you can't fix it.
Re: Can't Get Pressure In The Brake Lever [Re: Selden] #148386 07/03/20 08:24 PM
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Kenny4 Offline OP
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Originally Posted by Selden
Congratulations, and thanks for the analysis, which may help others avoid the same problem.


Well honestly, thanks be to Craig1 as he's the one who figured it out.

Kenny4


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