Problem: The lever sporadically will feel tight and have no loose play. However, the majority of the time, it doesn't fully push forward on it's own, leaving the brake switch not pushed in, and as a result the brake lights are on when I'm not braking.

Things I've done:

1) I've taken the calipers off and sprayed the crap out of the pistons with brake cleaner after pushing the pistons out 1/2". They didn't look that dirty to start so I didn't mess with shoving them into their bores.
2) I flushed fluid through the lines to ensure no air in the system. The brake lever is very firm when pulled back.

I played with it last night and I can make it go fully forward (on it's own) if I do this: pull the lever back a hair, then push it forward and repeat 3x. This leads me to think the master cylinder plunger that pushes the lever forward is stuck, or maybe the pistons still aren't clean. This is a dual front caliper setup.

I'm going to let a dealer look at it, but wanted to get people's opinions first.

Thanks

 

Matt
Do you want to bring it over tomorrow night?

 

Wish I could but going out of town for the weekend. .maybe next week sometime?

 

OK, Just let me know

 

Did you ever get this fixed? My 07 flhtc is doing the same thing.

 

Do you guys have the little metal wedge behind the switch assembly ?

 

I had the dealer look at it while it was in for other stuff and they said they applied some lube to the piston of the master cylinder. They didn't charge me anything and it seems to have made it better.

 

Try to make use that warranty before it goes away--had the same issue with mine and was able to convince an otherwise unhelpful dealer to give me a front master cylinder rebuild under warranty (probably b/c brakes are one of those important, hence "high-liability" things).

 

They could have had dot5 fluid instead of dot4. My MC locked up on me as well as my caliper. The MC lid said dot5 and for my bike it takes dot4. They think it ate up the seals etc. The warrantied the rebuild. Isaac moving at 35mph when it locked up.