Brake Lever Not Returning

Energy One

awg

Guru
Hello to everyone. I have a question. I have a 04 Chopper. The brake lever on the bars does not return all the way which causes the brake lights to stay on. I can take my finger and push it up the rest of the way. Is there an adjustment? Or is some thing worn out? The lever seems to have "free play". Anyone out there ever have this problem? Thanks in advance.
 

Little-Boo

Well-Known Member
Troop Supporter
Looks like its time to rebuild your front Master cylinder. Could be that the plunger is sticking or the spring is weak. I would just rebuild it and be done with. :2thumbs:

Carlos :whoop:
 

V

Guru
Hello to everyone. I have a question. I have a 04 Chopper. The brake lever on the bars does not return all the way which causes the brake lights to stay on. I can take my finger and push it up the rest of the way. Is there an adjustment? Or is some thing worn out? The lever seems to have "free play". Anyone out there ever have this problem? Thanks in advance.
Good time to upgrade to chrome!
 

Ray

Well-Known Member
Agrees with Little boo boo and BB. Mine did the exact same thing and rebuilding it fixed it. A little tip. When I blead mine I couldn't get all the air out, or it seemed that way. Like it had air in it!!!!!!
Red over at R&B's showed me what the issue was after I inquired someone of more knowledge and was starting to get ill. With the cap off the cyclinder, pump the brakes a few times easy then "tump" with your finger a few times. I think it was the third time he did it a couple air bubbles came out that were trapped in the chamber in the master cyclinder. He put the cap back on it and grinned.

Dot 5 brake fluid too!!!!!!

Ray
 

zipnz

Active Member
spring

I had the exact same thing happen to me on my '04 Chopper. It is most definitely the spring. Took it to Stroker's, they replaced the spring,(not sure if the old spring was weak or if it had broken) brake lever works as new. Master cylinder did not need a rebuild.
paul
 

Little-Boo

Well-Known Member
Troop Supporter
OK. Sounds good. Now the hard part. Where can you get a rebuild kit?
Try Lena at Strokers she'll hook you up. Just send her a PM which is what I have done in then past and got the parts quick.

mailto:lena@strokersdallas.com

Carlos :whoop:
 
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Little-Boo

Well-Known Member
Troop Supporter
I had the exact same thing happen to me on my '04 Chopper. It is most definitely the spring. Took it to Strokers, they replaced the spring,(not sure if the old spring was weak or if it had broken) brake lever works as new. Master cylinder did not need a rebuild.
paul
The spring was replace and it did not need a rebuilt kit :loony::loony: the spring is inside the master cylinder. Don't know how they got the spring out if it's the last component inside the master cylinder. Maybe it did not require a hone job, but once opened anyone doing the work would have common sense to replace the spring, piston and seals. Maybe yours is different but I don't think so :loony::loony: Just saying I could have my marbles scattered on this one.

Carlos
 

Ray

Well-Known Member
The spring, seems like if I remember correctly was pretty easy to get too. I had to use air pressure to blow the old seal out, kinda shoot across the garage. Best I remember it is pretty easy. If you can get away with just the spring , try that , but since I was already into it , I did the whole thing, pads and all. Be easy with those allen screws taking the top off, don't over tighten them. snug!!! was what I was told.


Ray
 

mobsta

Well-Known Member
Easy way to bleed the system is use a clean oil can,put a hose on the end and hook it up to your frt brake caliper bleed screw.Open the bleed screw slightly,pump the oil can forcing fluid up through the master cylinder.just sayn what works for me,good luck :cheers:
 

dale4713

Active Member
My '04 had same problem, whet to local dealer for parts and they just gave me a rebuild kit the mechanic had in back. said he didn't have part # and not to worry about it.:cheers: I would go ahead and do rebuild while you've got it apart it's easy.
 

Oldhvymetal

Member
What Mobsta's talking about is a technique called "reverse bleeding". Since going to 4 piston calipers, I do this all the time. It really cuts down on your time replacing brake fluid or rebuilding your brakes, or if you suspect an air bubble- when it comes time to bleed them. It's easier to do with rear brakes but is very effective for front ones too. Basically, it goes like this:

Fill the reservoir, and use a standard slow caliper bleeder screw loosening until you get a few drips then tighten the bleeder screw again.

Now take the clean oil can with DOT 5 in it and a plastic tube pressed on the nozzle of the can and connect the other end of the tube to the end of the bleeder. Loosen the bleeder screw again and press the can to feed the fluid UPWARDS until the reservoir is full, maybe (being careful to use tape and/or rags not to let it drip onto the paint) until it spills over the edge of the reservoir just a leetle bit, then cap the reservoir (a little more will spill when you put the reservoir cover on so be careful not to let the fluid contact the paint brake fluid will damage the paint). The end result is you won't have to bleed the brakes! By "reverse bleeding", no air will be in the system. The bubbles will go up with the fluid and pop at the top of the reservoir fluid level.

Here's another bit I'll add. Instead of an oil can, I use a plastic baby medicine syringe. They only hold about 2 or 3 teaspoons but that's all you should need. They're about a buck and a half each, and if you get decent ones and you wash them out quick they're reusable. Google "baby oral syringe" you'll get a bunch of hits... you'll find them at any decent drug store.

Once you get used to doing this you might be surprised how much time you save when bleeding brakes.

This might be on the "how to" posts already, I didn't look. Good luck all- c'ya out there soon!
Peace, Respect,
OHM
 
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