Sticking front brakes

[Waiex191]

Jacked up the front wheel.  Verified that the brake frees as soon as the lever is released. Got my son to help me.

Next we compressed the forks, I think to the stop, and locked them in place with a cam strap.  No signs of locking up.

So far that puts me at a loss.  The aftermarket brake lever is nice and free.

My brake lines from RPM came today. Can anybody tell me what these things are for?

[fj1289]

If I remember correctly - they are used to clock the fittings.  The "stic goes through the banjo to lever it around while you hold the fitting in a vice using the "clamp".

[Waiex191]

If I remember correctly - they are used to clock the fittings.  The "stic goes through the banjo to lever it around while you hold the fitting in a vice using the "clamp".

So, they do swivel.  I had tried by hand and failed, and thought I misunderstood.

[Waiex191]

Thanks, I ended up clocking one fitting a few degrees.  Also regarding your comment on aftermarket levers, I did find my lever was pushing in the master a little bit hands off. I filed down the stop that the green arrow is pointing toward.

[RPM - Robert]

That appears to be the stock lever for the 03-05 (06ish) FJR masters that are used with the blue spots. It should not have needed any material removed.

[Waiex191]

That appears to be the stock lever for the 03-05 (06ish) FJR masters that are used with the blue spots. It should not have needed any material removed.

Here is the item on ebay I bought:
https://www.ebay.com/itm/323930918730

They identify it as aftermarket.  It did look a little different finish than the broken OEM one I took off.  Also the bushing looks to be aluminum rather than bronze.  So I think it is a close copy.

[fj1289]

Hope that clears up the problem for you!  In my case it just slowly built up more and more pressure and locked up about half way to work.  Don't remember how I figured what the problem was - think I finally realized that was the last thing I had messed with! 

[RPM - Robert]

Yup pretty close copy. I didn't look close enough in the original picture to see the bushing was not brass.

[Pat Conlon]

Old brake lines look fine on the outside but can shed little bits of rubber inside.
This stuff can clog the Masters relief port.

Good on ya for getting new Spiegler lines....

[Waiex191]

Yup pretty close copy. I didn't look close enough in the original picture to see the bushing was not brass.

It was well-greased in that picture so would have been hard to pick out.

[Waiex191]

Ok, I'm back.  I can't believe the poor bike has been sitting for over a year.  I've done a lot on the airplane - some planned and some unplanned.  But I felt like I should get the airplane "finished" before I tackled the FJ.  Had no idea it would be this long.

First thing is I had to figure out where I was on the brake project.  Looked like I was down to routing my new brake lines from RPM.  I went with the dual lines and used a couple of loose adel clamps at the horn mounting bolts to control the routing.  Finished that, put the horn back on, and bled the brakes.  I did a reverse fill through the bleeder, then some conventional bleeding but was not getting pressure.  I tie-wrapped the lever to the bar overnight and that did the trick.  No more brakes sticking on.  My suspicion is that the aftermarket brake lever that didn't let the MC retract all the way was the culprit.  Thanks again fj1289.

First ride in almost a year - still rides like an FJ.

[chiz]

I don't know if you had the pistons out or put new pads in if you did though it could be something like what I did. Which was not clean the  pistons properly on my old ST1100 when I shoved them in to make room for the thicker new pads. This caused a jam up as the pistons would not return properly.
     Now I spray solvent on the exposed part of pistons and get a long enough thin cloth stick the end through and pull back and forth until they are shiny before shoving them in.Havnt investigated a simpler way.

[Waiex191]

I rebuilt the calipers, master cylinder, and pretty much everything.  New pads from RPM, new EBC rotors bought from somebody on the forum here.  I generally use isopropyl alcohol to clean brake parts.  Definitely not my first time doing brakes.  I'm pretty sure it was the aftermarket brake lever that I had to file down.

And now - the FJ is leaking fuel again.  Crap.

[Pat Conlon]

Bryan, do they use ethanol free fuel for aircraft?  Run a tank of Seafoam thru it....

[Waiex191]

Bryan, do they use ethanol free fuel for aircraft?  Run a tank of Seafoam thru it....

Pat,
We run 100LL in our aircraft which is great stuff but it has a lot of lead.  I have actually been running nothing but ethanol free gas for a couple of years as I got sick of tearing apart my carbs.  But this is not the problem - keep an eye out for a new thread.