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Let's see if we can get some brakes on this 1996 KTM 250 EXC
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Hi, I'm Francois from adventurebiketroop.com and in this video I want to give you an update on the KTM 250 EXC bike build
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It's been a while since I've worked on it and the main reason for that is I'm waiting for fork seals and I could only find them on eBay from France and they haven't arrived yet
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it's been more than a month now so I hope they do arrive the other thing is I
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haven't been able to get the brakes to to build up pressure so I took the brakes
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apart cleaned out the cylinders cleaned out the calipers removed all the old
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paint check the seals they were fine put it back in so it was quite a mission to
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get the pistons out so what I ended up doing was using a grease gun and that
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helped me or that with that I managed to push out the pistons it's quite a mess
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but anyways it works a treat then I put everything back together again put it on
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the bike and I started bleeding it but I've never bled brake from dry so without
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any fluid in it and and I didn't realize it's such a mission because I don't have
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any tools I don't have a vacuum pump so I am pretty sure that they are just air
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bubbles in it so I've spoken to a lot of people watched videos and what I'm
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going to try now is to use a syringe to pull out some of those bubbles So
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quite a lot of brake fluid went in there without anything coming out at the top
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You can see it's dry there so that makes me think there's a lot of air in there
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So I'm going to keep doing this and see if I can get brake fluid to squirt at the top
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I think I should probably actually clamp down the lever with the cable tie so that it's
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open so the air bubbles can come out. So let's do that. Okay, I think I'm onto something because there are a whole lot of bubbles squirted out when
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I pressed on the lever. Or maybe I'm just gonna keep pushing air bubbles up and then releasing them with the lever
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I'll show you the next time and then hopefully that works. Ok let's see if we can get more air out
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I think the level is actually raised now Ok no air bubbles this time I just gonna clamp it down open it up so if
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anything squeezes out it can release itself so I've clamped down the lever
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and the reservoir is full and let's see if we can squeeze out some more from the bottom up
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Making a mess as usual, let's see at the top
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Now let's try to bleed it normally and see if we can get pressure in there
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We managed to get breaks in the front. So what I ended up doing was to just squeeze it from the bottom with the syringe, trying
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not to let air bubbles in and I opened it at the top And then I just bled it normally which wouldn work initially and I didn realise that So it because of all the air that I can bleed it I was just compressing air bubbles so we got solid front brakes and now we gonna
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try the rear but anyways that worked it's so silly because it's such a simple
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problem that you just can't figure out at all if you don't know what you're
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doing so I just I try to squeeze out all the air for probably about 30 minutes
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without any luck but it's yeah if you just can get most of it out then from
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there it's just normal bleeding Okay so I tried the same on the rear, I ran out of time, the rear is not pressurised yet
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but the front is, front works perfectly, I managed to get the rear cylinder to pop out
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but it's not touching the disc yet or the pads are not touching the disc yet
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So there's still too much air in there, but I will get it fixed, I'm sure
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Hopefully it's not this aftermarket brake cylinder, the slave cylinder. Otherwise I'll have to get a proper Brembo one, a second name one
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But anyways, that's all for this week. I've managed to get the brake, at least the front brakes to work
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So we are making progress. Now if I can just find that 49.5mm fork seal
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If anyone knows where I can find an old 95, 96 KTM fork seals, please let me know
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Anyways, that's it for this week and I'll see you next time
