As y'all know, I ride an old shitheap of a Kwaka, and I tend to give it a bit of welly too, so maintenance is a constant battle against various bits that deteriorate as fast as I can fix 'em. Recently I've had to stop coming out on twisties rides, partially because I'm as busy as a one-armed man in a wanking contest right now, but mainly because my front brake lever has been coming right in to the bar before it starts doing much. Holster discovered this after we very narrowly avoided a 4WD that meandered out in front of us 2-up on the Gembrook road. Not much fun. And disappointing, since this used to be a 2-finger stoppie bike. Here's the steps I've taken to try to sort it out, and whether they made any difference in this case: 1) Bleed the bollocking things - fail 2) Bleed them again - fail 3) Replace pretty sorry-looking rubber lines with steel braided lines - fail (!) 4) Bleed again - fail 5) Disassemble master cylinder, replace piston and seals (thanks Kenny!) - fail 6) Crack the shits 7) Deep breath In my most recent attempt, I've stripped and cleaned both 6-pot calipers (thanks Pete the Pom and Roarin for advice and f*ckup-fixing), used a dremel with a wire wheel to gently remove all the built-up scum behind the seals, cleaned the caliper halves until I'd be happy to eat my dinner off them, replaced the seals, dust seals and o-rings with freshies (thanks to Troy @ Race Rep - he's the man for Kwaka parts) and reassembled. I've also put on a set of brand spanking new Metal Gear discs and pads, because the old discs were getting a bit thin (thanks to anonymous buddy). So I've pretty much cleaned, rebuilt or replaced every f*cking compnent in the braking system, and spent buttloads of money and time in the process. This is the kitchen sink approach to brake maintenance. I'll be putting the thing back together tomorrow, assuming I can get Cheng to help me with an unrelated fork job sometime tonight, and then I'll know if the situation's any better. If it's not, there'll be a bonfire at my house tomorrow with a Kawasaki in the middle of it. Bring marshmallows and other Kawasakis if you've got 'em.