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2011 FXDWG, My front brakes failed completely. Flush and refilled with dot5, brakes returned to normal but sometimes the brake light stays on. It seems like the lever is not returning to the fully open position. I can push it forward about 1/8" and light goes off. Spring maybe? Dirty? I'll pull the lever and see what's up. Any other ideas will help.
No need to pull the lever off yet. Mine had the same issue. Spray a quick squirt of non water based lube on the plunger and squeeze the lever in and out a few times. Sometimes they just get stuck.
2011 FXDWG, My front brakes failed completely. Flush and refilled with dot5, brakes returned to normal but sometimes the brake light stays on. It seems like the lever is not returning to the fully open position. I can push it forward about 1/8" and light goes off. Spring maybe? Dirty? I'll pull the lever and see what's up. Any other ideas will help.
Do yourself a favor and go buy the Harley P/N 45006-96C master cylinder repair kit it costs about $30.00, If it failed once and you brought it back to life with a fluid change, it will fail again soon.
Also Harley-Davidson has used DOT-4 fluid since 2006 or so, you have mixed fluid in your 2011 FXDWG... You need to do something soon as DOT-4 and DOT-5 fluids are completely incompatible, the fluids when mixed make goo.
In addition to what Mike suggested, take a very close look at the plunger on the switch. the tip broke off mine and behaved just like you describe. A new switch ~may~ be in order.
The "mushroom" broke off at the red arrows. In the pic I had already epoxied it back on, but that didn't hold. I ended up running a tiny pan head screw in there so I now have a fully adjustable front brake switch plunger. Works great!
Thanks to Mike for the heads up on the dot 4 / 5 dilemma. I knew HD had changed fluids but mine says dot5 on the reservoir cap. I did a thorough flush so there's not much mixing going on but as you said they are not compatible and may have gummed up the plunger. I'll try the clean and lube method first. If that fails I'll move on to the other suggestions. The reason the brakes failed in the first place is low old fluid. Thanks for all your help guys... I'll let ya know what the fix is.
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