Brake lever too stiff after swapping levers
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Joined: Jul 2019
Posts: 89
Likes: 12
From: TX
Brake lever too stiff after swapping levers
Hi! This is the opposite of the usual problem, so unsure how to address.
2019 FXFBS - I wanted to swap my chrome levers out with the black ones - bought the HD ones (non-adjustable). Install was fairly simple - followed the video at
The clutch lever is great (actually feels a little bit easier to pull - which makes no sense) - I verified that the clip at the bottom is in the right position.
However, the brake lever is really tight - as in, almost no play. With the old lever, I could pull it about half an inch or so before it would start applying the brakes, and even then, it was relatively gradual/smooth. I could never pull the brake lever more than half way in (so, it was not spongy/soft) - it was just right. With the new lever, it has almost no play. So, squeezing the brakes is using the tips of my index/middle fingers - where as with the old lever, I got max brakes when the lever was close to my middle knuckle.
The brake lever doesn't really seem to have any adjustments that I could have screwed up (that I could see) - and I didn't open the brake reservoir at all.
Any suggestions on how to make it a little softer? (I could buy the adjustable ones as a last resort, but trying to avoid spending another $250-$300 for that)
2019 FXFBS - I wanted to swap my chrome levers out with the black ones - bought the HD ones (non-adjustable). Install was fairly simple - followed the video at
The clutch lever is great (actually feels a little bit easier to pull - which makes no sense) - I verified that the clip at the bottom is in the right position.
However, the brake lever is really tight - as in, almost no play. With the old lever, I could pull it about half an inch or so before it would start applying the brakes, and even then, it was relatively gradual/smooth. I could never pull the brake lever more than half way in (so, it was not spongy/soft) - it was just right. With the new lever, it has almost no play. So, squeezing the brakes is using the tips of my index/middle fingers - where as with the old lever, I got max brakes when the lever was close to my middle knuckle.
The brake lever doesn't really seem to have any adjustments that I could have screwed up (that I could see) - and I didn't open the brake reservoir at all.
Any suggestions on how to make it a little softer? (I could buy the adjustable ones as a last resort, but trying to avoid spending another $250-$300 for that)
Road Master
Joined: Jun 2019
Posts: 952
Likes: 528
From: Richmond TX
This really sounds like an installation error. I wonder if your brakes are actually working. It's a stock lever. There is a switch mechanism in there to light up the brake light. I suggest you remove the lever and get a close look at how the parts assemble. If you don't have a shop manual this might be a great time to buy one, comes in handy for lots of stuff. Good luck getting it sorted out!
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Joined: Jul 2019
Posts: 89
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From: TX
This really sounds like an installation error. I wonder if your brakes are actually working. It's a stock lever. There is a switch mechanism in there to light up the brake light. I suggest you remove the lever and get a close look at how the parts assemble. If you don't have a shop manual this might be a great time to buy one, comes in handy for lots of stuff. Good luck getting it sorted out!
Looking at the shop manual, there really does not seem to be a way (that I see) to screw it up. Things either fit, or they don't. Only thing I can think of is that the part of the lever that depresses/activates the brake fluid is a tad bit too long? Very confused...
Seasoned HDF Member
Joined: Aug 2006
Posts: 24,536
Likes: 30,858
From: Pennsylvania
You could also bleed the brakes if you have not already done so. And if you have ABS or linked brake system, and have not flushed the brake fluid, now is the time to do so. Might also want to pull your caliper and check your piston function and make sure they retract all the way.
If you have ABS have you started the bike up and checked how the lever works with all the systems powered?
When you removed the stock lever, did you shim it like the manual calls for? By releasing the piston in the master cylinder you may have pumped the master cylinder up some. Try a short bleed (release of pressure at the bleeder) on the front brake system, then check the lever play.
Just some random thoughts of things to be checked.
If you have ABS have you started the bike up and checked how the lever works with all the systems powered?
When you removed the stock lever, did you shim it like the manual calls for? By releasing the piston in the master cylinder you may have pumped the master cylinder up some. Try a short bleed (release of pressure at the bleeder) on the front brake system, then check the lever play.
Just some random thoughts of things to be checked.
Thread Starter
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Advanced
Joined: Jul 2019
Posts: 89
Likes: 12
From: TX
You could also bleed the brakes if you have not already done so. And if you have ABS or linked brake system, and have not flushed the brake fluid, now is the time to do so. Might also want to pull your caliper and check your piston function and make sure they retract all the way.
If you have ABS have you started the bike up and checked how the lever works with all the systems powered?
When you removed the stock lever, did you shim it like the manual calls for? By releasing the piston in the master cylinder you may have pumped the master cylinder up some. Try a short bleed (release of pressure at the bleeder) on the front brake system, then check the lever play.
Just some random thoughts of things to be checked.
If you have ABS have you started the bike up and checked how the lever works with all the systems powered?
When you removed the stock lever, did you shim it like the manual calls for? By releasing the piston in the master cylinder you may have pumped the master cylinder up some. Try a short bleed (release of pressure at the bleeder) on the front brake system, then check the lever play.
Just some random thoughts of things to be checked.
I did shim the lever to prevent damage to the brake light button, I will try the bleed tomorrow (have to read up on how to do that first)
Thanks again!
Thread Starter
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Advanced
Joined: Jul 2019
Posts: 89
Likes: 12
From: TX
You could also bleed the brakes if you have not already done so. And if you have ABS or linked brake system, and have not flushed the brake fluid, now is the time to do so.
When you removed the stock lever, did you shim it like the manual calls for? By releasing the piston in the master cylinder you may have pumped the master cylinder up some. Try a short bleed (release of pressure at the bleeder) on the front brake system, then check the lever play.
When you removed the stock lever, did you shim it like the manual calls for? By releasing the piston in the master cylinder you may have pumped the master cylinder up some. Try a short bleed (release of pressure at the bleeder) on the front brake system, then check the lever play.
Thanks for the suggestion anyway.
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Seasoned HDF Member
Joined: Aug 2006
Posts: 24,536
Likes: 30,858
From: Pennsylvania
My 2019 trike lever does not have any play in it, begins to engage as soon as I pull the lever. I'm thinking you may have had a tiny air bubble in the master cylinder and removing the lever and putting a new one on let the air bubble escape back into the fluid reservoir. Just my hypothesis. As long as it is not engaging the brakes when you are not pulling on it all should be well.
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Thread Starter
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Advanced
Joined: Jul 2019
Posts: 89
Likes: 12
From: TX
My 2019 trike lever does not have any play in it, begins to engage as soon as I pull the lever. I'm thinking you may have had a tiny air bubble in the master cylinder and removing the lever and putting a new one on let the air bubble escape back into the fluid reservoir. Just my hypothesis. As long as it is not engaging the brakes when you are not pulling on it all should be well.
Thanks again
Seasoned HDF Member
Joined: Aug 2006
Posts: 24,536
Likes: 30,858
From: Pennsylvania
Did you try putting the old lever back on to see if it changes anything? Does not take long to swap brake levers.