Motorcycle Repair: Spongy brakes after caliper overhaul, spongy brakes, excessive travel

Question
Hi Mark,
I've recently rebuilt both front calipers on my 1989 Kawasaki ZX1000 B2 as they were seized on their sliders.  I've replaced the seals and slider boots and they now work great.

The problem now is that I have excessive travel on the brake lever!  I've bled the calipers with a one way valve device, but just can't get them to bleed successfully.  The brake lever feel was solid before the caliper overhaul, so I don't think it's the hoses flexing or master cylinder.  Also, there is absolutely no sign of fluid seepage.

Would you recommend bleeding without the one way valve?

Thanks,
Darren

Answer
Hi Darren,

I would switch between old school bleeding and the bleeder tool.

Air still exists in the brake system. Give it some time and bleed again. You may have to do this more than once before the lever feels solid again. Send me an email addy. I'll return a couple of tech files to assist you.

For optimum lever feel, use stainless steel braided brake lines. Rubber lines expand when brake fluid is compressed, especially with older lines.

Respectfully,
Mark Shively