Yeah that's a total bummer. Sounds like air is getting in there somewhere. I had a similar issue with the AP performance braided lined I got from Japan. Back brake was OK although it did take quite a while to bleed. I ended up unbolting the master cylinder and orienting it so it was pointing down and there was nowhere for air to get trapped. Front was a different story. I tried everything I knew for weeks to get it bled but if I sprayed water around the various fittings almost all of them were leaking. Total crap. In the end I put the original hoses back on and had it bled within 15 minutes. I still want to get a decent set of braided hoses on there though as the originals visibly flex a bit. Even though I had both ends bled I ended up borrowing a reverse bleeding kit from a mate. Basically a pump to pump fluid under pressure from the bleed screw on the caliper up instead of the normal bleeding method. Worked really well. Got quite a bit more trapped air out. Got the best results that way by far. Vacuum gauges can suck air in if there is even a hint of a leak anywhere. I've heard some even just use a big syringe to do it. Sorry if I'm telling you what you already know anyway.
Are the new copper washers as thick as the old ones? I had to grind a little bit off my banjo bolts so that they would seal.
Sounds like its pulling in air from somewhere ..... a continuous stream of bubbles has to be coming in externally
I went and saw my mechanic and he had a few ideas which I tried, his advice was first to ensure the pistons were all the way back as that's a good place that air gets trapped. The other was to try and reverse bleed them using gravity and make any excess air come backup up through the brake fluid reservoir, he also suggested one way bleed valve. Brake now works. So here is where I fall on my sword, I went down to Supercheap and bought a one way bleed valve, that was helping but still no firm pedal, I then decided to remove the Tyga rear sets and put the stock ones back on, then is dawned on me, maybe the adjustment on the pushrod wasn't right, so I removed the pushrod and added another 5-6mm on the shaft then reassembled it. One attempt at bleeding it and I had Instant brake. It seems when I fitted the rear set, I didn't adjust the pushrod as I assumed it would be fine from what was on the stock rearset. Im off the garage, first off Im going to start her up because I love the smell of 2 stroke in the morning, then I am going to put it all back together
Ahh chris so its all new for no reason!! That rear brake is going to feel amazing though don't we all hate those little things!!
Well done Chris, bike looks amazing specially now that she has........BRAKES!!!! Seems so long ago when we played around with it, pleased she is now ready for rego. Wonder if @risky will up his bid ................probably not! By the way.......................great photo's mate. Time to enjoy your RS250
