95 zr 580 efi, 6000 miles on it. Not really sure what happened. I started out yesterday morning and while the sled was moving I could here the brake pads rubbing on the rotor. While it was doing this the brake handle got really stiff (didn't have to move it far to apply the brake). Because the sled is so old I went along with it and eventually it stopped. But once it stopped the brake handle got mushy and went 1/4" from the handle grip. But at least I was able to stop the sled. Of course once we reached our furthest destination the brakes locked up again, this time tighter and to the point of not being able to drive the sled, and the brake handle was really tight. So I opened the bleeder valve. It was hard to get at so I don't think I got it back to close position. After that I had no brakes the rest of the way home (except for my feet). Also note from when I left my house until I got home my brake fluid reservoir was full the whole time. My questions are:

1. Is this simply air in the lines causing this?
2. Will bleeding the system fix this?
3. Why didn't the fluid in my resevoir get used?
4. Did I loose brakes from opening the bleeder valve?
5. The brakes have always worked fine. About 2 years ago I did snap off the reservoir and simply put a new one on without doing any bleeding. The brakes were used for about 20 minutes without knowing my reservoir was missing. Could this be where the air is coming from if that is what the problem is? 2 years later?

A really hard feeling to the handle is usually a result of caliper failure or a collapsing brake line,however due to the fact that the resevoir was replaced and NOT bled,I would start there. Take a small piece of tubing that fits tight over the bleeder screw,put one end over the nipple on the bleeder screw and insert the other end into a HALFFULL clear glass jar of brake fluid,making sure that the hose stays in the fluid at all times. Open the bleeder screw a turn or two.Remove the resevoir cap and empty all old fluid out,if you dont have a turkey baster or other means of sucking the old fluid out, leave it in there.SLOWLY and I mean SLOWLY pull the brake handle until the fluid is close to being depleated in the resevoir,filling it with fresh each time it runs low.You will repeat this for 4-5 cycles of new fluid through the resevoir,or until there nothing but clean fresh fluid coming from the caliper into the jar.Once satisfied its all clean and clear,tighten the bleeder tightly,then remove the tube and glass jar.

You should have good brakes at this point,if not....
crack the braided steel hose connection loose from the caliper and give the handle a squeeze,if fluid seems to flow freely and the handle is operating right,remove the caliper and either rebuild or replace.
If the handle is sticky or does not return back all the way replace the Brake master cylinder assy.


If you replace any components,or loosen any lines you will need to repeat the bleeding procedure all over again.

good luck :div20:

RedF5 is right on the money, you need to bleed your brakes and check the caliper. You either have moisture in your brake fluid or your caliper is sticking on and causing the fluid to heat up until it builds up pressure in the system. Try bleeding all of the old fluid out first.

Good luck