Hello fellow zukers,
I finished installing my Trail Slayer kit on my Tracker and now I am having problems with the brakes.The problems are that I bled all my brakes and there is no air in the lines but the pedal is still soft. Also when I press the brake pedal with the Tracker running the idle surges and then is fine after I release it. I know that the front brakes are working fine cause when I took it for a test drive last night I pressed on the pedal hard when going down my drive way and the front brakes stopped good. There is also a weird noise that comes from the proportioning valve on the frame so I was wondering if you folks would know what is going on?

Every symptom you have except the firm front brakes indicates air in the lines.  Proportioning valve noise says its one half of the valve tan the other, the noise is it trying to compensate.  The idle surge is probably the same thing, the diaphram is extending further than normal trying to compensate, pulling more air out of the manifold, computer senses mixture leaning and compensates giving idle surge..

My bet is you still have an air pocket somewhere.  Im pretty confident Im correct.

Not to sound arrogant but are you sure sure that every thing is tightened and not leaking??  This could also cause the problem...

Its just an annoying bubble.  Try getting more aggressive in your bleed.  Back flush it if you have to, or power bleed it..

What's the differance in piston area of your new brakes vs. your old brakes. I'm assumeing you are now using the Toyota brakes with the axles. If they are larger you will notice an easier pedal with more travel. Just to be certain bleed your brakes a bit more, brake fluid is cheap insurance. Check your lines fully for anything streached, stressed, or cracked. It wouldn't hurt to have a friend press the brake pedal while the engine is running to hear for any brake booster whistles. Kinda shot in the dark at this point.    NMc

Well I have also installed the kit myself. I did however upgrade to vented rotors and twin piston front calipers. I also rebuilt all the brakes on my rear axle. I am 99% sure I am not running the proportioning valve on the rear of my sidekick. I remember seeing one on a previous model I had but my current 1994 does not have one.

I agree, you must have air somewhere. I can lock up the tires on pavement if I wanted to with a stock booster and master cylinder.

I also had custom lines made for about 50 bucks for my front calipers, and I am running an allpro stainless braided line in the rear from the axle to the frame. All the rest of the line and junciton blocks are stock suzuki.

I would ditch the proportioning valve in the rear too.