OK, So I am looking around but I can't find anything on how to tighten up the lever (take the play out of it) of the front brake lever...
There is just enough play / relax in the lever that it causes the rear brake light to stay on...
I have tried adding more fluid, but nothing is causing it to come back to full front... I have to ride with the lever pushed forward with my finger... I am just talking about maybe 1/8 to 1/4 of an inch... it is that way while riding and while parked... Do I need to take the whole assembly apart? And if so what am I looking for beside the plunger to push the lever back to full front and stay there?

 

ANY Idea(s)?

 

I'd start by bleeding the brakes. If that doesn't help I'd start to suspect the master cylinder.
I had a rear master cylinder go out on my 08 Fatbob and it was covered under the warranty.

 

When those new grips were put on, did you do the "cardboard shim in the brake lever" trick? The brake light switch may be broke. If you search on these three words: "cardboard brake light", many threads come up with information. Good luck!

 

thanks for the reply and the search tip... I did use the shim trick, but I don't under stand how shimming it on the back side of the lever will help the switch in the front...
Anyway I took the switch housing apart to look at it... I see the clip that goes over the top of the switch and there was little to no play with sliding in and out... I did go ahead and place a small bit of plastic folded up to the back, behind the switch and the housing wall.
Tilted the bike upright off the jiffy stand and added a small bit of DOT 4 to the master.
I also made sure the whole assembly was pushed in as tight as I could on the handle bar.
I gave it a test and it seemed to work. Then set it upright to start it up and noticed that it was stuck on again, but easily went back off...
Is there supposed to be a boot over the plunger for the brake cylinder? It is just metal.
Thought about wrapping some electrical tape around the end of the lever to give it that little bit of extra push... Seems like the black levers are milled just an "RCH" smaller than the factory. ( I reinstalled it to test it and it seemed to work) But i have had the black one on for almost a year, maybe I just never noticed...

 

do a forum search. There were just a couple of great threads on this a week or so back. Hope this helps.

Christian