Z1OwnersClub GB

Hi All, I've just finished rebuilding my J and changed the front brakes to GPX twin pot floating calipers and 310mm twin fixed discs. It all seems to work except that the lever is coming right back to the bar before the brakes come on. I've bled the system more times than I care to remember and changed the master cylinder to one of Zpower's replacement units that should have a suitable capacity. Any ideas on how to reduce the travel in the lever?[/img]

have a look at this old thread - lots of options here to try.

http://www.z1ownersclub.co.uk/forum/vie ... e+bleeding

Just had the same problem on my J. New caliper seals, new master cylinder repair kit and new braided lines tailor made by Al Marshall (pukka job Al). I had a syringe and tube picked up from ebay to set the fork oil levels. I attatched the syringe and tube to the caliper nipple and while pumping draw the air out with the syringe, you will get there a bit quicker if you help the air out. Another thing I did was to push the caliper pistons all the way in before bleeding therefore starting with less air space in the system. Not sure if this helped at all but it didn't do any harm either. The lever still pulled back to the grip but I walked away from it for a day or two allowing any air left in to rise to the top then tickled the lever which seemed to do the job.
ps 2 different size syringes and a load of different bore tubes of ebay came to about a fiver with delivery.

Warwick,
I had loads of hassle doing my brakes a while ago. I fitted new calipers and it turned out that one side didn't line up square with the disc, so as you applied the brakes the squiffy one had to slightly bend the disc to grab hold. The disc was acting like a big spring washer. There was not enough travel in the lever to take up this travel and apply enough pressure to work the brakes. Took me a week of evenings, bleeding & phaffing around to suss that out.

How did you solve it Pigford?

Pigford,,, If i were you i'd be very very carefull how you explain this one

ROTFL.................

come then Piggy I want to know...........
how did you solve the problem ????????

Just a thought,
when i was racing i had a new oil can that i only used with brake fluid, I fitted a clear pipe to the end of the can and then the other to the bleed nipple on the caliper and then i could reverse bleed it by pumping the oil can. It worked great and was very quick for the times i fell off and had to sort the brakes out between races. you have to be careful though not to let air into the fluid in the can

Well my answer was to remove the offending article, and now I just run on one front disc! It is a Gixxer unit with a Tokico 6-pot caliper tho', 10 x better that a standard Zed brake

The second (and favourite) option, is to shim the caliper so it lines up correctly with the disc

Geoff Meager wrote:come then Piggy I want to know...........
how did you solve the problem ????????

He took the offending caliper and disk off!!!!!!!!!!!!!! No disk - no caliper - no problem He may have been better off just aligning the caliper and disk properly in the first place

Rich, I can obviously type quicker than you, bet you feel stupid now

Pigford wrote:Rich, I can obviously type quicker than you, bet you feel stupid now

Well I thought you were never going to reply so I thought I'd better put the record straight for you

GRASS

I hear a rumour that you are making your bike go even faster by removing the front master cylinder - is there any truth in this