Progress today
One step forward, one back 🙂
Filled rear brake reservoir and attempted to bleed at the caliper with the Mityvac. Pulled fluid through the system, but could not get any hydraulic pressure – pedal does not push pads. Tried several passes. No luck. Air in the master maybe? Will learn more about that and try again later.
Filled front brake master cylinder and attempted bleeding, starting at the left caliper. Could not get vacuum with the Mityvac. As soon as I cracked the bleed nipple, pressure at the Mityvac immediately dropped to zero. Same problem on the other side. Pulled no fluid. Also tried manual method pumping the lever while nipple open, then closing. No effect.
The only part of the system I haven’t taken apart by now is the master cylinder. It seemed to pump fluid when I first tested on the bar, but could be the problem.
So, I removed the master cylinder assembly and disassembled. It was difficult to get the circlip out, but I eventually did. Two rubber piston seals looked good. Metal piston did not look exactly like the service manual in shape, but obviously functioned. Piston was scored and scratched with sharp metal edges in two spots. Crash damage from my slide, perhaps.
Filed the damaged areas, wirebrushed, and polished the piston.
Also cleaned the inner bore of the master. It didn’t have any apparent scoring or crusting.
Reassembled the master with brake fluid lube and attached the lever assembly. Piston action feels smooth. Ready to reinstall on the bar and connect lines.
Continued disassembly of the right handlebar by removing the grip.
Then separated halves of the switch assembly. Pulled out and spent a while with sandpaper cleaning that once-bright orange kill switch. Looks much better afterward.
Not yet figured out how to get throttle cables disconnected and the switch housing and throttle tube off the bar.
Ran WD40 down both throttle cables until it appeared at the carb ends. Cables are clear and move freely. Throttle twist action is still very stiff, and does not spring back. Further disassembly, cleaning required. Probably some clean and lube needed in carb linkages as well.
Next
Getting harder to avoid pulling the carburetors: the last major mechanical system on the list. Probably need to do that to get the throttle cables off, anyway.