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[TallyClassic]

Dummy me, in rushing the replacement of a set of Lyndall Zpads, I loosened the larger caliper bolts instead of the pad pins on the right caliper.  I discovered my error when I loosened the brake fluid resevoir cap and the caliper started leaking.  I tightened up the bolts and got the leaking to stop.

Upon installing the pads and mounting everything back up to the forks, I needed to pump up the pads and obviously add more DOT4 fluid.  Strangely, the calipers wont pump up.  There were some bubbles of air coming out of the relief hole in the resevoir.  So I'm sure some air got in.  I've got Speed Bleeders in each caliper, so I know a full flushing of the air is necessary.

My concern and question is why no fluid at all was going down the lines?  The whole thing just very air-bound?

[erniezap]

Do a complete flush of the system (probably due anyway) and see if it clears up.  By splitting the caliper you may have ruined the seal, meaning that the caliper needs to be rebuilt

[DESERTBEAR54]

Keep squeezing the brake handle slowly and keep adding fluid. It will take quite awhile for that air to escape the system or back bleed by running a bleeder line also from caliper into brake fluid and let the air gravity bleed into fluid while squeezing brake handle. You will have to crack zurk fitting and sqeeze the brake 3 times then close it. Keep repeating this process until that brake handle gets hard. Good Luck!!

[TallyClassic]

Yep, I'd just done a flush last fall.  But I had the new wheels put on at ThunderBeach. (Thx Myrtle Bch!!)  Old pads were howling and knew they had to be replaced anyway, (26K miles).
Only loosend the caliper bolts 2 turns, didn't even see the caliper halves split.  But the leaking fluid was evidence enough.  Just find it weird how I cannot get any fluid down there, no matter how many pumps of the lever. 
Now that I think of it, it makes sense that there's probably so much air in the line that the lever makes it's little push and the compression of the air pushes the fluid right back up.
Thanks guys.

[ordlord11]

Lets us know the results good or Bad... What did you think of Thunder Beach?

[grc]

Try hooking up a manual vacuum pump to the bleeder valve to assist in moving the fluid from the reservoir to the caliper.  That should speed up the process, but you will need an extra set of hands.  One to deal with the vac pump and bleeder, another to keep the reservoir full and to pump the lever.

Jerry

[TallyClassic]

Results are that I totally over-reacted.  Just a bunch of air in the line that needed to come out.  Went for first ride yesterday to seat in the Zpads.

ThunderBeach was good as usual for the Spring version.  Saw a few extra vendors who were skipping Myrtle Beach, but not as many as I thought there'd be.  Way too nutty at night and parked 'em, walking to a nearby club.  We have a place there and the post-local reaction was a bit negative.  A larger ThunderBeach may not be a good thing, quite a bit of rudeness was reported.  PCB is real close to eliminating Spring Break, if we're not careful, we could be next.

[scooter 6262]

Use speed bleeders sold on ebay no need to close bleeder to bleed they have a check vale in them they work great

[LarryB]

easy way out. Make sure the reservoir is full, put cover on, get a zip tie and squeeze the lever hard as you can and zip it. flick the brake lines to release bubbles, allow to sit over night, cut zip, open and check fluid, add if necessary, cover up and check it out.

[roadrunner]

Service tech suggested to lightly clamp the brake leaver to the grip.  I use a piece of velcro, brake lever nice and firm the next day. Tech said keeps the air out of the system.  Ride safe!

[LarryB]

Service tech suggested to lightly clamp the brake leaver to the grip.  I use a piece of velcro, brake lever nice and firm the next day. Tech said keeps the air out of the system.  Ride safe!

Isn't that what I just said?

[jfh]

easy way out. Make sure the reservoir is full, put cover on, get a zip tie and squeeze the lever hard as you can and zip it. flick the brake lines to release bubbles, allow to sit over night, cut zip, open and check fluid, add if necessary, cover up and check it out.

Neat trick! Thanks