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Old 09-25-2015, 04:14 PM   #1
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KTM 690 front brake issue

Not too long ago I wiped out jumping a log near lake conroe, and when I picked my bike up I noticed I broke off my front brake lever. It sat parked until the new one arrived and I installed it without a problem.

After riding about 8 miles with the new lever installed I noticed my front brake engaging. I had to adjust a bunch to keep the front brake from engaging while riding. Ever since my brake pressure (on the lever) will swell and fade during riding. Its almost a 1/2 of difference, to where I cant make the brake light come on without locking the front up.

I've since bleed the front with a vacuum bleeder and thought it solved the issue, but after riding some its still the same.

any ideas before I go to motorcycles unlimited
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Old 09-25-2015, 04:29 PM   #2
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probably up the master cylinder or where the brake lever hooks up to the it....should be an easy fix....

if you can't seem to find it Im sure Patrick and his boys would be able to get it going in no time and cheap
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Old 09-25-2015, 07:13 PM   #3
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Take the master cyl assy off the bars and hang it up with the lever pointing to the cieling. Try to do it so the front brake line is straight, up and down. Wiggle the line and tap it a little at the banjo fitting. leave it for a day or two and give it a good shake every time you walk by it. Then when you put the brake assy back on the bars pull the lever in a little and zip tie it to the grip so there is a little pressure on it. leave it for a day if you can. If that dont fix it it aint air.
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Old 10-05-2015, 06:14 PM   #4
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re bled the front brake on saturday, seemed okay that night, and this morning, but this afternoon without riding, the brake lever was super firm again. Seems like the temperature might have some kind of effect on it. Now I will be seeking professional help. :(
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Old 10-05-2015, 07:42 PM   #5
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Is it an aftermarket lever or OEM? A lot of chinese aftermarket levers have this problem where you have to shave the portion that makes contact with the plunger on the master cylinder. It's a big problem when you've been riding and the heat causes your fluid to expand. Your brake could lock up when you're riding.
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Old 10-05-2015, 08:16 PM   #6
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they're aftermarket, but I'm fairly certain at this point that I f'd up the master cylinder or the abs module, although abs works just as good as ever.
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Old 10-06-2015, 07:13 PM   #7
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so, in the mornings before work and all the way there, the brake lever is great. Sitting mostly out of the sun all day at work the brake lever is very very firm when I go home in the afternoons. Its been this way consistently since its been chilly in the morning.
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Old 10-07-2015, 08:19 AM   #8
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http://www.gixxer.com/forums/33-gene...ouncement.html

Did you use DOT 4 brake fluid?
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Old 10-07-2015, 07:23 PM   #9
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no, 5.1

just realized my sport bike stand wont work on and 21'' front tire, so i'll be driving over to a local shop to have my tires changed, and see if i can get something figured out on this brake bs
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Old 10-07-2015, 07:35 PM   #10
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Is DOT 5.1 what it says on the cap? The EU manual says not to use DOT 5, it might be different between models. Good luck!
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Old 10-07-2015, 08:03 PM   #11
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yeah, my manual says specifically not to use dot5, to use 5.1 or dot4

but bleeding and flushing the fluid has had literally no effect of this issue
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Old 10-07-2015, 10:32 PM   #12
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have u tried tightening the banjo bolt on the MC and caliper?

ur bike ABS?
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Old 10-07-2015, 11:01 PM   #13
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Abs module need bleeding? I'm not familiar with how they're set up on bikes. How do the brake pads looked? Caliper stuck? Bent rotor? Bad MC still seems like the main culprit. Try disassembling it or rebuild it possibly. Just throwing out ideas.
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Old 10-08-2015, 06:58 PM   #14
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Quote:
Originally Posted by BYRDMAN View Post
have u tried tightening the banjo bolt on the MC and caliper?

ur bike ABS?
I have not but will, when I get the wheels back on and yes I have abs.

Quote:
Originally Posted by cuong-nutz View Post
Abs module need bleeding? I'm not familiar with how they're set up on bikes. How do the brake pads looked? Caliper stuck? Bent rotor? Bad MC still seems like the main culprit. Try disassembling it or rebuild it possibly. Just throwing out ideas.
I'm not sure if you can bleed the abs module. The way the shop manual specifies is to use a positive pressure setup at the caliper. I used a vacuum bleeder, but like I said it had no effect on the brakes. no stuck calipers, and plenty of pad left, and no bent rotor
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Old 10-09-2015, 01:03 PM   #15
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Had this happen with a r6. Never could figure out what happened. Drained the reservoir and bled the master and it seemed to fix it.
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Old 01-16-2016, 04:50 PM   #16
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cycle shack north in conroe had my bike for 3 days, and all they can come up with is trying to sell me a new lever

so I went straight to Motorcycles Unlimited and we'll see what they come up with
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Old 01-21-2016, 08:07 PM   #17
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Motorcycles Unlimited is awesome!

Patrick and his crew solved my issue, which might have been a burr inside the master cylinder. Its true whats said around here, Motorcycles Unlimited is worth going to no matter what side of town you live in, for me its worth the 40 mile drive...one way
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