Hello all, first time poster, although I’ve lurked for awhile trying to research answers to questions that I’ve had with my bike over the years…on to my post, I have a ’96 TRX200D Type 2, have owned it since I was a teenager. It has given me 20 years of excellent service, and still runs like a top!

I’m planning on selling it here very soon and have been working on it the past few days trying to get the brakes back in good working order. The only problem I’ve had is with the front hydraulic brakes. I bled the lines first, checked the shoes which were good to go, rebuilt the wheel cylinders, and started to fill the system back up with new brake fluid. After vacuum bleeding for a good two hours and not really getting anywhere I buttoned it back up full of fluid to see where my problem might lie.

I clamped a vise grip a couple inches downstream of the master cylinder, and got a rock hard stop. I then clamped the line above where the three lines come together, and again got a rock hard stop, so master cylinder is good to go. However once I clamped on either right or left lines underneath where all three join, the brake lever had free play all the way in. I’m guessing there is an air leak somewhere in the area where they join but I’m not sure. I don’t see any brake fluid leaking anywhere on any of the lines so at this point I’m guessing it’s a pin hole somewhere leaking air into the system…

Am I right in assuming I’ll need new brake lines? Or could it possibly where they all join up? There are no bulges in any of the lines btw…any help would be greatly appreciated, thanks guys…