curvy brake caliper reinstall not going well

Folks,

Took both calipers off my 650 SX, stripped one, rebuild with new seals etc, ready for install. The second one the pistons are jammed, it was my intention to refit the complete caliper, and the skeleton of the second, bleed the system and use hydraulics to push the stuck pistons out.

For some reason when I tried this today, the lever would not go firm (the technical term haha). It was like no fluid was getting through to enable a bleed. There was fluid getting into the caliper as fluid was trickling out of the bleed nipple, but no pressure.

Anyone any ideas? Its probably something really simple I am missing, but am just off the night shift so not all of my cylinders are firing.

Cheers

Gary.

Oh, also noticed that only one of the calipers has the brake line guide bit, this is normal..?

[yorkie_chris]

Air stuck in banjo bolt somewhere, fiddle with it to remove high points and allow bleed. Then bleed out of banjo bolts themselves.

Especially bad on S bikes... M/C points uphill. And on stock brake lines with 1-2 splitter thing on bottom yoke.

Think I got you dude, cheers for reply.

Just so I am sure what you mean, effectively the 2 holes in the banjo bolt itself have to be in line with the travel of the brake hose? Ill mark the bolt if that is the case and line it up

Might have to semi rebuild other caliper, going to be a PITA to do this when it hanging off the flexi lol

[yorkie_chris]

no no just tighten them correctly, if you try to line holes up they will end up either mullered or loose.

Never mind ports inside bolt.... for master cylinder bolt bleed, I just lean bike to left. This allows air in bolt to run up into reservoir.

Cool, its on the side stand anyways so is leaning left, Ill have a wee play about with bike try force air out.

Cheers

[maviczap]

I'd used a big syringe connected to some clear tubing and sucked the hydraulic fluid through on mine. Managed to get it pretty good and then got the rest of the air out of system in the usual way.