CVO Technical > Wheels/Tires/Suspension/Brakes

Spongy Brakes after caliper rebuild

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Meestro16cvo:
Hi all, i just rebuilt all 3 calipers on my 2016 CVO Limited. Bled the brakes like normal using a vac bleeder at each caliper and I still have a spongy brake feel. Using DOT 4 Fluid. I even bought the set up from ITM to cycle the ABS motor, still not right. I really feel that air is still in there as if you do a double pump, the lever is hard at about half travel. Anyone run across this? I think I’ve run about 2 quarts of fluid through this system. Anyone have any tricks? I used the cycle pro rebuild kits including pistons from JP cycles. PN 10230876.

flhman:
Ever figure this out ? Kinda going thru the same thing.

SIKBIRD:
Definitely air in the system.  Tap the lines with a screwdriver handle from the caliper all the way to the reservoir then with the cover off and EVERYTHING COVERED if using DOT 4, pull the lever in and let go quickly (let it pop back out) as many times as your forearm can stand.  Keep working with it and eventually you’ll get all the air out.

SIKBIRD:
Thinking back, my dad had this problem with his 03 RKC.  It was original brake fluid so wasn’t an issue of air being introduced to the system.  On his, the issue turned out to be sticking pistons in the calipers, I took his brake pads off and carefully pushed the pistons out with the lever (BE VERY CAREFUL, if the pistons come completely out of the caliper, you gotta do a complete tear down and rebuild) cleaned the pistons with simple green and an old toothbrush then lightly lubed them with cable oil. Put it all back together, pumped he brakes up and they were tight again.  Before I did this he would have to pull the lever nearly all the way to the grip before it got tight.

flhman:

--- Quote from: SIKBIRD on November 02, 2025, 08:54:25 PM ---Thinking back, my dad had this problem with his 03 RKC.  It was original brake fluid so wasn’t an issue of air being introduced to the system.  On his, the issue turned out to be sticking pistons in the calipers, I took his brake pads off and carefully pushed the pistons out with the lever (BE VERY CAREFUL, if the pistons come completely out of the caliper, you gotta do a complete tear down and rebuild) cleaned the pistons with simple green and an old toothbrush then lightly lubed them with cable oil. Put it all back together, pumped he brakes up and they were tight again.  Before I did this he would have to pull the lever nearly all the way to the grip before it got tight.

--- End quote ---
Thats where my problem started, right caliper was messed up, only 2pistons were moving, I rebuilt both calipers, put it all back together and started bleeding it, just when I think I’m good, more air bubbles come through. Had a buddy helping, he had to leave, so I parked it, did the zip tie on the lever, gonna mess with it some more today. Fingers crossed !

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