I purchased new pads and rebuild kits for my 82k mile Concours. I've never had a whole heck of a lot of confidence with the braking system, so I figured I'll try replacing everything that can be replaced easily. I rebuilt the master earlier this year.
The bike came with a 3 line Spiegler stainless line setup when I got it at 74k miles. I pumped out all the fluid, removed the calipers, blew out the pistons with compressed air, and replaced all the seals. I cleaned up the pistons real nice and got them seated in the calipers. I put everything back together, filled the master cylinder and started the painstaking process of sending fluid through the system. I have a Mity-Vac which helps this procedure, but I still find it to be a real PITA.
Anyway, it's all done now and I'm getting clear, bubble-free fluid from both calipers. But I've got almost no pressure at the brake handle. I have those knock-off adjustable levers from Ebay, and I have to put them in the furthest setting to keep the lever from hitting the grip. I do get stopping power in this position but it's definitely not right. I used almost an entire large bottle of brake fluid bleeding both sides over and over, and now I'm kinda at the end of my patience.
I've now read about zip-tying the lever to the grip overnight and it is currently sitting in my garage with the lever in said position.
What am I missing? Should I have filled the calipers with fluid before hooking them back up? Do I need to re-do this bleed job somehow? Never had this much trouble with bikes in the past. I have a SS1000 coming up on the 15th, so I need to get this sorted out.
Thanks for any assistance.