WELL, new lines arrived today. Popped them on, new crush washers and all. The system is still exhibiting the SAME symptoms.

Just to support the fact that my methods of bleeding aren't a factor, I did just reinstall a MC on my F4i, and that flush/bleeding was a breeze.

So what's next? Replace/rebuild master cylinder? The other two MCs I tested the system with were both 5/8" as opposed to this unit which is an 11/16". However, shouldn't that STILL be able to build enough pressure?

 

Follow this guide and you should be good

DIY: Front MC Service 07-10 CBR600RR (lots of pics) : Honda CBR 600RR Sportbike Forum : 600RR.Net

 

UPDATE: Ok, before jumping the gun and buying a MC rebuild kit, I went over my current bike collection, and I pulled the 11/16" NISSIN MC off of my 07 ZX6R. Almost an identical unit, aside from the reservoir mounting bracket.

NOTHING CHANGED! That's the FOURTH Master Cyl I've tried on this system with no luck, same symptoms. Am I crazy, or does that rule out everything but the calipers? How could this be??

 

That would be my thought. Guess instead of the MC to rebuild, you'll be rebuilding calipers. That is strange though. You didn't see any leaks coming from the calipers and the pistons were moving well?

 

WELL, I'm a complete numskull. After receiving my new calipers, I put the bike up on the table to do the install, when I suddenly realized exactly why this has been happening.

THE PREVIOUS OWNER PUT THE CALIPERS ON BACKWARDS! Hence, the bleed nipples where upside-down, and retaining air. Somehow in my state of confusion I had not noticed this. As foolish as the PO was for putting them on backward, I feel even more stupid for not noticing.

Lol, anyway, I flipped the calipers around, bled, and brakes feel great. Thank you all for your contributions, and I hope someone can learn from my silly mistake, and make sure the calipers are in the correct orientation!

 

I feel your pain, I once wrestled a week with my old Peugeot 405 MI 16:s rear brakes that was also upside down, with the exeption that when I followed the haynes manual to the letter I saw in the pictures that the nipples were supposed to be pointing down, so I assumed there is some kind of a pipe or something going into the "roof" of the cavity. I could not get them bled no matter what I did, finally gave up, paid myself sick to have the car towed to a PSA-car specialist who phoned me about an hour later that the car's done. I asked WTF, HOW, he replied to me the 2x4 version has the same brakes as the 4x4, only they are supposed to be removed when bleeding, cause they are UPSIDE DOWN from the factory!