front brake lever problem

Discussion in 'Softail Models' started by astrorock, Dec 31, 2009.

  1. astrorock

    astrorock Member

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    hello all, i have a weird problem.. my front brake lever will not return fully, and the brake light will stay on. if i push the lever back the brake light will turn off. i have checked the switch and it is in correctly and moving freely.. the brake works fine, it's like there is a missing return spring or something..

    any thoughts..
     
  2. harleyargo

    harleyargo Member

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    I have had to replace bushing before and sometimes spray WD40 around plunger.
     
  3. Breeze3at

    Breeze3at Well-Known Member

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    If you do replace the brake fluid, make sure you use what is printed on the master cylinder cover. HD has used DOT 3,4, and 5. I don't remember what year they went from 5 to 4. I think Hobbit has you on the right track if your lever is sluggish on the return. Also you might be extremly low on fluid.
     
  4. kemo

    kemo R.I.P

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    I had to do my master cylinder for same reason, lights stayed on. I ended up strectching the spring. I would not spray wd40 around the m/c, I would pull the lever and put some teflon grease on the pin and bushing. You should consider buying a rebuild kit for the m/c if you are going to strip it.
    kemo
     
  5. NEWHD74FAN

    NEWHD74FAN Experienced Member Retired Moderators

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    Previous posts have you covered, just be very dilligent about cleanliness, clear water over rags initially; then using only 100% alcohol or fresh brake fluid to flush new parts when rebuilding. Make sure you use the appropriate brake fluid for your master cylinder. May also want to look in Self Help section for details on how to bleed the braking system.
     
  6. 2000classic

    2000classic Active Member

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    Might try a little silicone spray on the plunger and pivot area to make sure its all free. Then if needed go to the more complex ideas.:)
     
  7. Iceman24

    Iceman24 Well-Known Member

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    Good point w/the cleanliness & also be very careful w/the brake fluid b/c it's corrosive to paint/finishes! Might be best to lay a cover over the tank & area(s) below the reservoir...
     
  8. Jack Klarich

    Jack Klarich Expert Member

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    Have also seen this problem with dot 5 brake fluid, it can crystalize and cause the seals in the master cylinder not to return causing the light to stay on
     
  9. astrorock

    astrorock Member

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    thanks guys i'll have to check all that stuff out.. i think the plunger is not returning fully because there seems to be a space between the switch and the plunger, and the lever..
     
  10. NEWHD74FAN

    NEWHD74FAN Experienced Member Retired Moderators

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    One other thing, did you have the control shell halves disassembled? There is a small copper wedge that could have slipped out causing the brake light plunger to bind and cause binding within. One of the reasons why a penny or shim is used to hold the lever while disassembling the control switch. Just something to watch out for...before setting off on m/c rebuild.