Usually those brakes have to be bled from the caliper up to the master cylinder using a syringe and hose, you might try getting a bike shop to bleed them for you but I've heard from others that you DO NOT tell them it came from a mini motorcycle and say it's from a mt bike instead or they won't even look at it.



Marzocchi makes forks for KTM bikes; yours look like they are from a 50 SR, they also make the forks for the ktm65's, but with a real motorcycle brake

 

ya the older ktm 65sx used marzocchi forks like those. I have the brembo master from the 02 or 03. You made need a power bleeder or reverse bleeding it may work. If you dont know that means opening the nipple and using a brake syringe and pushing the fluid up into it and forcing the bubbles up. Also on my brakes I used a small tool and tapped the line while pumping it and I got a lot of bubbles up that way. Of course start at the bottom and tap upward to force the air up. Hope that helps. If not it could mean your master needs a rebuild.

 

Hey thanks for the input. I might just take it to a bike shop like zwieble said. I've tried the reverse syringe method with no results. Although I haven't tried there trtr tapping trick yet. The bottom of the master cylinder was pretty nasty dirty so that may have something to do with it. Thanks for the help and input.

 

Make sure your lever adjustment is all the way out (if it has any). Try taking the caliper off the forks and turning it in all different directions while tapping it with a wrench to try and get any air bubbles up and out of the system. Sometimes air gets trapped in the banjo bolts too. If it still doesn't work, then you probably need to reseal the master and caliper.

 

Ye, check, if the lever has a bit of free play and adjust it all out. I installed this same complete brake on my Marzocchi 35mm Shivers. It works hell better than the standard Formula 2 piston brake. I only touch the lever and the bike imidietly stops. Much better setup!! I bled it in normal way-few times push the lever and then worked with the bleeder on the caliper. I made it few times to change all the fluid for a new one and i had no problem with that. Im also using the oversized brake disc and I used the stock caliper bracket for the 200mm disc and 2 piston standard caliper, only made the holes in the bracket bigger from 6 to 8mm. I would recommend this setup for anyone alse here, much more stopping power, no fading also. It looks hell small, but works really good!

 

Thanks for the info. I feel better about fixing this setup now.