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Discussion Starter #1
I've got a 2003 zx6r with around 39000 miles on it. I flushed the front brakes a while ago and noticed there was some fluid leaking from the bottom of the reservoir where it connects to the tube to the MC. I went ahead and got one of those ebay special brake fluid reservoirs https://www.ebay.com/itm/Universal-Brake-Tank-Oil-Fluid-Reservoir-Cup-For-Yamaha-YZF-R1-R6-R6S-FZ-7-Color/171488605648?hash=item27ed8475d0:m:mlBkld6q3ZCisHUWohEE2zw for my bike since the old one had some slight spider cracking and was due for a change anyways. After changing the reservoir, there is still brake fluid leaking from the bottom of the reservoir. Ive tried everything from getting new hose clamps, trying new brake hose tubing, getting another reservoir just in case the one i got was bad, going back to the oem one, and even used this https://www.amazon.com/XFasten-Waterproof-10-Foot-Weatherproof-barrier/dp/B07C96QLBY/ref=sr_1_4_sspa?ie=UTF8&qid=1528824136&sr=8-4-spons&keywords=seal+tape&psc=1 stuff to try and contain the leak. Brake fluid is STILL leaking from the reservoir. Does anyone know what would cause this to happen?
 

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Is the leak because you have over filled the reservoir? Fill it just above the 'low' line, and see what happens.

If not, is it due to something at the MC end of that line?
 

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Discussion Starter #5
Is the leak because you have over filled the reservoir? Fill it just above the 'low' line, and see what happens.

If not, is it due to something at the MC end of that line?
I made sure to nearly underfill the reservoir multiple times at different levels. It still leaks at the correct level/ low level/ high level. Ive gone through so much brake fluid while testing it. Luckily brake fluid is pretty cheap. I have no idea what could possibly cause
this.
 

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I'm stuck with thinking that the problem is not the reservoir... Too many exchanges without a change in the problem. From there, lines or MC seem to be the only options.

Any corrosion, pitting, cracking? Has a rebuild been done?
 

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Are you sure something else is not going on. What you are describing sounds literally impossible. Are you sure you are cleaning your work after your installs, are you sure that your bike is not parked in a chalk at the same exact spot and you have a roof leak or something, are you sure you're not constantly using the wrong tube size?
 

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Discussion Starter #11
Are you sure something else is not going on. What you are describing sounds literally impossible. Are you sure you are cleaning your work after your installs, are you sure that your bike is not parked in a chalk at the same exact spot and you have a roof leak or something, are you sure you're not constantly using the wrong tube size?
Yes i clean my work thoroughly to check for future leaks. I am sure it is not a roof leak unless brake fluid leaks from the roof causing the paint to strip on my triple clamp. I used the correct tube size from tygon which is 8mm inner diameter.
 

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Discussion Starter #12
I'm stuck with thinking that the problem is not the reservoir... Too many exchanges without a change in the problem. From there, lines or MC seem to be the only options.

Any corrosion, pitting, cracking? Has a rebuild been done?
I did notice some rusting on the steel braided brake lines where it connects to the caliper. And the only cracking i noticed was from the previous oem brake reservoir which is why i changed it out for the cnc aluminum one. I also dont see any imperfections on the MC or any other imperfections on the brake lines besides where it connects to the caliper. There's no leaking where the line is rusty at the caliper.
 

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Discussion Starter #13
Ok so i ordered these hose clamps https://www.amazon.com/Hilitchi-Adjustable-8-38mm-Stainless-Assortment/dp/B01IOE4RQQ/ref=sr_1_5?ie=UTF8&qid=1529006963&sr=8-5&keywords=hose+clamps because it seems like the oem ones just arent strong enough to make a good enough seal around the brake reservoir connection. I cranked the clamp on REALLY tight to the reservoir and it seems to not be leaking as of yet. Even if this does fix the problem permanently, shouldn't the oem hose clamps be plenty strong enough to prevent leaking from the reservoir? I guess i just find it strange that kawasaki would use those weak pinch clamps instead of these worm gear clamps in the first place like they do for the radiator hoses.
 

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Ok so i ordered these hose clamps https://www.amazon.com/Hilitchi-Adjustable-8-38mm-Stainless-Assortment/dp/B01IOE4RQQ/ref=sr_1_5?ie=UTF8&qid=1529006963&sr=8-5&keywords=hose+clamps because it seems like the oem ones just arent strong enough to make a good enough seal around the brake reservoir connection. I cranked the clamp on REALLY tight to the reservoir and it seems to not be leaking as of yet. Even if this does fix the problem permanently, shouldn't the oem hose clamps be plenty strong enough to prevent leaking from the reservoir? I guess i just find it strange that kawasaki would use those weak pinch clamps instead of these worm gear clamps in the first place like they do for the radiator hoses.
My clamps are pretty strong. Maybe you have stretched yours out too much and caused it to lose its strength?
 

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Discussion Starter #15
Ok so i ordered these hose clamps https://www.amazon.com/Hilitchi-Adjustable-8-38mm-Stainless-Assortment/dp/B01IOE4RQQ/ref=sr_1_5?ie=UTF8&qid=1529006963&sr=8-5&keywords=hose+clamps because it seems like the oem ones just arent strong enough to make a good enough seal around the brake reservoir connection. I cranked the clamp on REALLY tight to the reservoir and it seems to not be leaking as of yet. Even if this does fix the problem permanently, shouldn't the oem hose clamps be plenty strong enough to prevent leaking from the reservoir? I guess i just find it strange that kawasaki would use those weak pinch clamps instead of these worm gear clamps in the first place like they do for the radiator hoses.
My clamps are pretty strong. Maybe you have stretched yours out too much and caused it to lose its strength?
I ordered brand new ones with the same diameter. Idk my problem is fixed for now but im just worried that down the road it might show up again
 
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