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I bought my bike from my brother in law after he spilled it going about 40 MPH. He only had it 2 weeks. Damage to the bike was minimal, windshield broke, highway pegs snapped off clutch lever scraped up, right rear foot peg/muffler bracket broke.I have all of the above changed out and repaired. Tank didn't even get a scuff. My brother in law not so lucky. Major knee reconstruction. Healing. Now for the cause of the spill....First of all I am no authority on the repair subject. On the other hand I have never taken a vehicle to the garage to have it fixed. He told me the front brakes locked up on him. I got the bike home and opened the master cylinder, full of rusty sludge and the return port was crystalized and caked shut. I disassembled the master cylinder, cleaned it thoroughly removed all the lines, disassembled the calipers and cleaned them. I had to rod out the small opening in the master cylinder. I called my closest Kawasaki dealer and asked if I was on the right track. He graciously said yes. I fashoned me a vaccum catch jar with two fittings on top to attach to my vaccum pump and to the bleeder screw on the calipers. I vaccumed new fluid through the system and let it purge a little extra. I caught all the yuck in the jar. Works like a charm. Kawasaki told me it was a result of poor maintenance and moisture had built up in the system. They recommended changing out brake fluid every year or so...I hope this helps someone avoid an accident.
 

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Ma Kaw says every 15,000 miles or two years, which ever comes first, change the fluid. I'm due on the mileage.
 

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My front brakes are seized, out of no where. Have had the bike for two years and had it in the shop recently. Today I went out on my lunch and the bike would not move, the forks would compress as I gave it gas, like it was trying to do a brake stand. Any one have any ideas for a quick fix so I can get home in and hour and a half from now... or do I need to call am tow truck? Currently 5:30 eastern. Help???
 

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romeobravo172
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842 Posts
Open up bleeder valve on each caliper, take a small screwdrive and gently push the pistons away from rotor. Keep in mind on your way home will only have rear brake!!
 

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romeobravo172
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842 Posts
Sounds like poss a master cyl is not letting fluid back into resivor, if both calipers are stuck is prob master cyl, if only one side might just be the piston stuck.
 

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..have a vulcan good day!
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Open up bleeder valve on each caliper, take a small screwdriver and gently push the pistons away from rotor. Keep in mind on your way home will only have rear brake!!
x2 I used a 1.5 " putty knife, you might get away with a butter knife.
I closed the bleeder valves after pushing pistons, just didn't use front brake until a complete fluid change.
hope this helps
WilliamTech
:pepper:
 

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romeobravo172
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842 Posts
Could be a collapsed brake line that only lets fluid go one way(to caliper, but not back to master), can't tell from outside, this happens on the inside of hose. If you get it unstuck, take your time getting it to wherever and then figure out what went wrong!!
 

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Went out at 5:30 and it is freed up, was able to push the bike with my tip toes. So I'm lost...on my drive in today it was fine, sat for approx 4 hrs and it was unmoveable and then 2hrs later, free as a bird. Does this make sense to anyone? We'll see how it is when I go out at 7..
 

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romeobravo172
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I would not use my front brakes until I got it home or somewhere I could do a good diagnostics on it. Would not want to be sitting at a red light with my front (or rear) brake locked up.
 

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I got it taken care of. It turns out the master cylinder was all gummed up and just needed to clean it out and free up the return for the brake fluid. This was a crappy problem to experience.
 
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