Bad brake hose or master cylinder?

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31 Mar 2016 13:47 - 31 Mar 2016 14:00 #718542 by car5car
Bad brake hose or master cylinder? was created by car5car
I couldn't move rear brake pads apart until I turned hose banjo bolt out one turn to drain some fluid. Brake fluid doesn't go back to master cylinder.
I think there are 2 possible problems:
clogged brake hose
clogged hole in master cylinder.
Which one most likely?

96 Yamaha Royal Star
82 Yamaha Virago 920
Last edit: 31 Mar 2016 14:00 by car5car.

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  • GKBO
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31 Mar 2016 18:01 #718578 by GKBO
Replied by GKBO on topic Bad brake hose or master cylinder?
More than likely your teeny tiny return port in the master cylinder is clogged.

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06 Apr 2016 21:27 #719661 by RonKZ650
Replied by RonKZ650 on topic Bad brake hose or master cylinder?
I think the 80ST is terminally ill. My gosh, you have 25x more problems than I've had in 40yrs of KZs.

321,000 miles on KZ's that I can remember. Not going to see any more.

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07 Apr 2016 06:18 #719698 by New 750
Replied by New 750 on topic Bad brake hose or master cylinder?
Also the inside of the rubber hose could be collapsed, preventing fluid return.

1977 kawasaki KZ750

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07 Apr 2016 08:04 #719715 by Nessism
Replied by Nessism on topic Bad brake hose or master cylinder?
Any time something you describe happens a full teardown is in order. Pull the pistons out of the caliper and clean the insides, replace any pitted pistons and the seals, reassemble. Do the same for the master, being careful to make sure the small return port is open. Also, replace the brake line. Also again, do the front at the same time.

Agree that your bike is a disaster. That's what happens when people don't do maintenance and just wait for crap to bust before doing any work.

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  • z1kzonly
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07 Apr 2016 08:49 #719727 by z1kzonly
Replied by z1kzonly on topic Bad brake hose or master cylinder?
Plus 1 , All of the above. Ya want to be on the cheap? Start with the brake hose. Get a fine piece of .035" mig wire from a welder.
A can of brake clean (Bad stuff is better with chlorinated solvents or tri clor).
Have an air compressor.
And a 6 pack of Beer!
AND ALWAYS WEAR SAFETY GLASSES
And if you get that far, you can clean it out.
If you get farther? If you try and blow the pistons out with high air pressure 100 PSI! make sure your fingertips are out of the way!

Livin in "CheektaVegas, NY
Went thru 25 of these in 40 yrs.
I SOLD OUT! THE KAW BARN IS EMPTY.
More room for The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
Starts everytime!

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07 Apr 2016 09:26 #719730 by MDZ1rider
Replied by MDZ1rider on topic Bad brake hose or master cylinder?
Reassemble and repeat, but this time loosen the banjo bolt at the M/C. If the pads open, problem is in the M/C. If not, bad hose. It's most likely going to be a clogged return orifice in the M/C. It's tiny and easily blocked. Hoses rarely collapse shut. They bulge or leak. If you've got a blocked hose, a complete flush and rebuild are in order. Actually a complete rebuild is in order either way.

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07 Apr 2016 10:35 #719733 by Nessism
Replied by Nessism on topic Bad brake hose or master cylinder?
Yes. likely the return port is clogged. But why? Answer: because there is sludge in the system. You can clean the blockage but the sludge is still in the system. You can NOT clean out the chunkies by flushing the fluid. The inside of the system has scale on the parts, including inside the brake line. Put new fluid in the system and watch it start to turn dark and contaminated within a month.

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