1) Buy a bleed bottle/filler that will fit YOUR kart. I susopect a 'universal' one will work but I don't know the OTK:-
http://www.spellfame.co.uk/acatalog/kart-brake-bleeding-tool.html
2) Place kart on stand. Empty out the old fluid, if possible, into suitable recepacle that you can seal and take to the 'dump'. Ideally, rebuild the brake systemn with new seals but.... IOf you can'r rebuild, try to get as much old fluid out as you vcan by LIGHTLY blowing (via a tube) into the open master cylinder while the rear bleeds are opnen. Agai, ideally, ttip the kart on it's rear bumoer to make sure all the fluid is out. Possibly, even leavihng it over-night like this.
3) Now.... fit bleed bottle, fill with fluid, open the bleed vent on ONE side of the caliper and let the fluid flow until it begins to come out of the caliper. Close that side, top-up bottle, open the other side and repeat. This should let a lot of the air excape but it's not ready yet!
4) GENTLY press the 'pedal' which should dislodge some of the bubbles in the master cylinder. If that gently refils the bottled and takes bubble WITH it.... all well and good, repaeat GENTLY until no bubbles are dislodged from the master sysliner into the header-bottle.
5) Lightly tap the master cyclinder and caliper plus the 'pipes' to try to dislodge any bubbles stuck to the sides. Re-fill the bottle and open the bleed on the first side again, FRACTIONALLY.... you want the fluid to leak but NOT to SPURT out. That should remove more bubbles. Continue to tap, lightly, the caliper until you can see that NO bubbles are coming out with the fluid. The do the same on the other side of the caliper. Make CERTAIN that the header bottle is full all the time!
Close off the bleed tool, drain excess fluid back to the can. Close the system and wipe away any spilled fluid and test the brake pedal.....
Assuming everything is fine, now check your pad-to-disk gap (both sides) and adjust however you can to give a VERY slight gap. There's no simple answer fopr that as there are SO many types of disks, calipers, automatic and manual adjusters that I can't cover them all.
If you have a 'spongy' pedal, then you have not removed all the bubbles. Was there a 'loop' in the brake pipe which trapped bubles at the top? Were the bleeders NOT at the top of the caliper, etc.. Look for obvious ways of making sure those 'odd' spaces don't contain air by moving the kart so all those bubbles can flow to the Capiper and can be bled from there and repeat those last stages again.
That should cover it.
ian
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OTK brake bleeding by 'TheROTAXkidakaTKMkid' (23 Mar 2010 @ 18:31)
