Hydraulic brake issue

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zoombyu

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I picked up a dirt buggy go kart and the rear brake didn't seem to do anything, front two were fine. Noticed the brake pad was half on the disc and half (top area) off. In my mind it made sense it didn't work because pressure against the pad was angled so the piston probably got bound up.

Took it apart and welded the mount to a proper location to allow for the entire brake pad to make contact with the disc. Took the caliper apart and was able to slide the piston in and out with a little bit of force (worked on many automotive disc brakes so it's movement force was consistent with them). Put it all back together and bled the line but the piston does not want to move when the brake is depressed. From its current position it has movement room in either direction based on what I can manually move it.

Any thoughts? Maybe I still have air in the line somewhere so the line isn't pressurized enough? Fluid is coming out the bleeder valve so there is fluid movement from the reservoir to the caliper.

Thanks, Jason.
 

OzFab

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I can think of three possibilities:

1. Master Cylinder is not operating correctly; you mentioned fluid movement from the reservoir but, that doesn't rule it out; if the seal in the M/C is damaged, it will not pressurise; when the bleeder is open, there's no pressure so it will move fluid; as soon as you close it, there's pressure & the fluid will find the path of least resistance...

2. The caliper piston seal is leaking; same principle as M/C leak...

3. There's still air in the system...

One question: With the system sealed, if you operate the brake repeatedly, does the fluid level drop?
 

zoombyu

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With the system sealed there is no change in fluid level. M/C and caliper are clean and dry so I didn't suspect a leak. There are 3 lines leaving the M/C, two for the front brakes, which work very well, and one line for the rear which is not.

How much fluid would I expect to bleed threw the rear line to consider it bled? I didn't get much (1/16" to 1/8" on the bottom of a red solo cup) so maybe I need to bleed it more? The line is about 70" long.

Thanks.
 

zoombyu

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Well started bleeding and broke a front caliper. The caliper casting busted and the "finger" fell off :( Dual piston M/C, apparently I should have been bleeding each piston separately. Live and learn. Got a replacement, took the M/C apart and cleaned it up, drained all the lines, put everything back together and started bleeding. Now I have all 3 brakes working as expected. Thanks guys !
 
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