Repair / Problems / Brakes / Brake fluid is leaking

Brakes

Brake fluid is leaking

Do not rideAlso called: wet brake hose, fluid at the caliper, brake reservoir empty, leaking banjo

Rubber dust boot on the master cylinder
Rubber dust boot on the master cylinder
Master cylinder plunger shaft with spring and circlip
Master cylinder plunger shaft with spring and circlip
Two-piston caliper pistons and seal groove: a worn seal leaks
Two-piston caliper pistons and seal groove: a worn seal leaks
Square-section caliper piston seal: it pulls the piston back off the disc
Square-section caliper piston seal: it pulls the piston back off the disc
Corroded brake plunger with rust and dirt: seizes the brake
Corroded brake plunger with rust and dirt: seizes the brake

You see wet or crusty fluid on a hose fitting, caliper, under the brake lever, on the wheel or on the ground, or the reservoir level keeps dropping. Brake fluid is clear to brown and feels slippery; it is not oil. Any leak lets pressure out and air in, and fluid on the pads ruins them.

Is it safe to ride?

No. A leaking brake can fail without warning.

Quick checks first

  • Wipe everything dry, squeeze the lever and press the pedal hard for a minute, then look again.
  • Look at the reservoir level in each reservoir, including the CBS reservoir.
  • Look at the pads: are they wet or dark?
  • Check paint near the leak: brake fluid blisters paint.

Diagnose it step by step

1Where is the fresh wetness? Follow it upward to the highest wet point.

  • At a banjo bolt or bleed nipple: go to step 2.
  • On a hose or metal pipe: go to step 3.
  • Under the lever, at the lever boot or at the rear master cylinder: go to step 4.
  • At a caliper piston or between caliper halves: go to step 5.
  • At the CBS unit (K-Light 125 type): go to step 6.

2Banjo bolt or bleed nipple.

  • Fit new sealing washers on both sides of the banjo and tighten to the model torque (K-Light 125: 30 N·m). Do not over-tighten a leaking banjo or nipple. Then bleed: Replace brake fluid and bleed the brakes.

3Hose or pipe cracked, rubbed or swollen.

4Lever or master cylinder.

5Caliper.

6CBS unit or its pipes.

  • Check a combined braking system (CBS). The K-Light 125 manual describes a fail-safe setting of the CBS adjusting bolt that lets the rear brake work alone when the linked front circuit leaks. It is a workshop measure to move the bike, not a repair.

7After the repair, is the lever firm and the level steady after a week?

  • Yes: fixed.
  • No: recheck all joints; a second leak is common on old systems.

Clean spilt fluid off paint and tyres at once with plenty of water. Fluid on a tyre makes it slippery.

Causes, most likely first

Cause How to confirm Fix
Old banjo sealing washers Crust or wet at banjo New washers, tighten, bleed
Loose or damaged bleed nipple Wet at nipple Tighten to model torque or replace, bleed
Cracked or rubbed hose Damage seen when bent Replace hose, bleed
Caliper seal Wet at piston, oily pads Rebuild a brake caliper
Master cylinder cup or cap seal Wet under lever or at cap Check the brake master cylinder
CBS unit seal Wet at CBS unit Check a combined braking system (CBS)

Reference values (K-Light 125)

Item Value Source
Brake hose banjo bolt 30 N·m K-Light 125 manual, PDF p. 64
Fluid DOT4 K-Light 125 manual, PDF p. 65

Related problems

Sources
  • K-Light 125 manual, PDF pages 33, 62, 64, 67

Values marked K-Light 125 are for that reference bike. Use your own bike's manual for its values. Text CC BY-SA 4.0, Transitions Lab.