Line should last forever unless a split occurs. That would become a leak of fluid and the lever would keep coming into the bar.

Sometimes the pads need to run into the disc esp if the disc is worn. Check the caliper moves freely on the slides and those slides don't create too much play although there will be some. Replace pins as required.

I don't believe that brake lines last forever. There is still a Teflon core and Kevlar sheath beneath the stainless braiding, all these can break down over time, especially given the neglect that some owners show their brake fluid.

One thing I've noticed on several of the used Gas Gas ECs I've bought over the years is the way the cable ends up routed tends to make the brake line kink about halfway up the fork. I just had to replace a line because it kept kinking and collapsing at that spot. Improved the feel dramatically.

Re reviewing this thread, and getting desperate again I've ordered a new brake line as mine has been kinked in the past so we'll see.

I've also just borrowed a master cylinder off a mate's 2014 which is 11mm like mine. Should try Sunday but if it works will put mine back on so just brake line test.

I bought a cheapo CR250 copy mc some while back. Didn't work out. Had 15 cast on it. That can't be right, took apart and it's a 12mm. China.com.


. . , and I bought an XR400 caliper to cover every base but won't see that for a couple of weeks. And my Renthal brake pads should be here any day.

Well. . . .

OK so new line and borrowed master cylinder. Immediately feels firmer. But I had moved my lever bite point in.

Brakes still whine a bit. Next loop I fit the Renthal pads replacing worn EBC.

OK this is good.

Put my old master cylinder on. Hard to bleed and almost give up but suddenly it comes right. Probably as I have less stroke with lever set a ways in. But my fingers are stronger closer to the bar so I like it like that.

Is it worse? Maybe. Maybe not.

Brakes are now acceptable but still could be 1 finger better.

caliper brake + master cylinder problem?

Well xr caliper should turn up in a week or so for next ride.

Well it showed up today.

. . . And it the exact same thing as the 07 caliper. Same 27mm pistons.
Mounting bracket is different.

I mounted for giggles and cause I love bleeding brakes so much.

If nothing else I got a near new set of genuine Nissin pads and a good pad pin.

Strangely the new Renthal pads showed some unused area on the non piston side. Just maybe the original caliper is a bit spread. Or just sliders are never perfect.
Pic won't load but imagine it.

I put the Renthal pads back in for fair comparison and will check to see if that evens up a bit.