XS850 - Monoshock & USD Fork (pics pg 13)

Re: XS850 - Monoshock & USD Fork

1fasgsxr said:
The calipers are from a 636 ? Take em apart...they are simple..possibly just a clogged passage
Click to expand...

Clogged passage? Wouldn't that keep air and fluid from traveling through them, not allowing air to travel through them? It seams like at least a few seals need replaced, which by looks of it, cost about as much as a replacement set of calipers in working order.
 
Re: XS850 - Monoshock & USD Fork

I could also buy the seals themselves here: http://www.kawasakipartshouse.com/oemparts/a/kaw/500b4513f8700223e4795858/front-brake

Looks like part #43049B for $8 each.

Or #43049...

Edit: Looks like this comes with everything needed to fix both calipers: http://www.ebay.com/itm/05-06-KAWASAKI-ZX636-NINJA-ZX-6R-NEW-K-L-FRONT-BRAKE-CALIPER-REBUILD-KIT-32-1318-/400732524568?hash=item5d4d851018&vxp=mtr
 
Re: XS850 - Monoshock & USD Fork

Wiper and seal. it's like a stanchion (fork) seal has a dust wiper then the O-ring seal. The question again becomes "why" why is it leaking that bad? need to inspect the cups and bores the all same, buying random parts not knowing what is actually needed is what dealership techs do :eek:

To remove the cups, disassemble and with a double layer of rags around the caliper use a blow tip with rubber or plastic cone and give the inlet a few bursts of air 100psi is plenty nuff just don't jam it in and pull the trigger... nice little bursts until they pop out in the rag. If one comes out and the other(s) is/are still in hold the one(s) against the wiper just enough to seal.
 
Re: XS850 - Monoshock & USD Fork

Tune-A-Fish said:
Wiper and seal. it's like a stanchion (fork) seal has a dust wiper then the O-ring seal. The question again becomes "why" why is it leaking that bad? need to inspect the cups and bores the all same, buying random parts not knowing what is actually needed is what dealership techs do :eek:

To remove the cups, disassemble and with a double layer of rags around the caliper use a blow tip with rubber or plastic cone and give the inlet a few bursts of air 100psi is plenty nuff just don't jam it in and pull the trigger... nice little bursts until they pop out in the rag. If one comes out and the other(s) is/are still in hold the one(s) against the wiper just enough to seal.
Click to expand...

Cool, thanks for the advice. I totally agree. I want to diagnose to the point that I know what is wrong before buying parts. Just making sure I know all of my options before pulling the trigger on something.
 
Re: XS850 - Monoshock & USD Fork

If your caliper seals are gone they will leak fluid everywhere. In other words, if they don't leak, the seals are OK.


The MC on the other hand may not leak, but will not work properly if the piston seal is worn.
 
Re: XS850 - Monoshock & USD Fork

I agree...But it seems treitz is not able to pressurize the system to find out where the leak/problem is, somewhere it's pulling air... I would at this point start at the beginning with one caliper in the system i.e. remove one line from the double banjo... bleed the master including the "master bleeder" hook up the single line disconnected from the caliper held above the master and pump it full, pinch the banjo and hook it up loosing as little fluid as possible and try bleeding it. You have to get pressure in the system to find the problem. I can't remember ever having this much trouble bleeding a brake system, but do remember an Audi A-4 that had a clutch slave that I went through a gallon of fluid before it finally popped an air gap in my face and worked awesome from then on.

Some days you eat the bear and some days the bear eats you :eek:
 
Re: XS850 - Monoshock & USD Fork

I had the same problem with my A4. Turned out to be a busted pressure plate though haha. Damn stg3 setups :/. My gsxr slave I have for my KZ440 has an bleed valve. I've experienced issues if it's not bleed correctly. It essentially needed burped. Had a large air pocket that the fluid just kept going around. I dont know if this was discussed but has the fluid been discussed? Meaning the right fluid got not only the lines but the lines and the calipers. You are using the right fluid right?
 
Re: XS850 - Monoshock & USD Fork

Alright, so I ran what we are calling the "xb" test with a stack of washer on the master. And sure enough, there is an air leak in the master. So I'm going to get that fixed up, then I'll look at the calipers again. The fact that the calipers are not leaking fluid crossed my mind as well. I'll run a few more tests after I have the master taken care of.

Yeah, pretty sure it's the right fluid... but I'll double check.

Then the question still stands... rebuild kit for my master: http://www.kawasakipartshouse.com/oemparts/a/kaw/500b4510f8700223e4795857/front-master-cylinder

Or, for slightly more, this mater (which may or may not also need rebuilt...): http://www.ebay.com/itm/261808027701?_trksid=p2060353.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT
 
Re: XS850 - Monoshock & USD Fork

treitz said:
Hopefully it's in better shape :)
Click to expand...

Well I drug you in so if it fails, I will give you 50% and pay shipping for the whole shebang... deal?
 
Re: XS850 - Monoshock & USD Fork

Alright guys. Back at it!

The new MC showed up. I installed it, tested it with the "xb test" and it wasn't leaking. So that's good news!

I bench bled it, then connected the lines and pumped the lines full of fluid holding them above the MC. Attached them to the calipers without losing much fluid at all. While performing a traditional bleed process I could get some fluid to flow through the calipers to the bleed hose, but not much. It would push out about an inch with of fluid in the line, and then just stop there. Brake never got harder to squeeze. Then I connected the vacuum tool and had the same results as before. Sucking through about 80% - 90% air. Seams like the seals in the calipers HAVE to be the next thing I check.

However, there is still no fluid at all leaking from the calipers. But I can't imagine where else the air leak could possibly be.

I guess the next step is to disassemble the calipers and inspect them.
 
Re: XS850 - Monoshock & USD Fork

That's what I was thinking. Could have a "lumpy" seal that's allowing air in, or something stuck between the seal and the piston. I had a guy bring in a goldwing that would "bleed" but never really got stiff. Found out his piston was pitted so badly that it was just letting it all go past his seal. However, there was a bunch of fluid coming with that, so maybe that's NOT your case :(
 

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Re: XS850 - Monoshock & USD Fork

Well gentlemen... we have liftoff! The bleed nipple on the top of the master cylinder that I asked about a while ago... yeah, all I had to do was bleed that first. Then, bang. 10 minutes later I was done.

First ride was OK. Still need some fine tuning, and the clutch cable is still super stiff. Thinking I'll start with a new cable and go from there.
 
Re: XS850 - Monoshock & USD Fork

Nice, did we skip this step in the beginning or was/is the old master shot?
 
Re: XS850 - Monoshock & USD Fork

Tune-A-Fish said:
Nice, did we skip this step in the beginning or was/is the old master shot?
Click to expand...

I did skip this step with the old master cylinder... however I still THINK it's shot because I did that "xb test" and heard air escaping and no pressure being built up. However it might be worth testing again just to see if I can sell it.
 
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