brake adjustment
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Joined: Aug 2014
Posts: 70
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From: Upstate NY
brake adjustment
'84 Super Glide FXRP-EVO-5 speed
My brake light stays on because the front brake handle is activating the switch. There is basically no free lever movement before the brake applies, causing the switch to keep the brake light turned on. How do I adjust to free up the lever a little?
Thanks, gregjo1948
My brake light stays on because the front brake handle is activating the switch. There is basically no free lever movement before the brake applies, causing the switch to keep the brake light turned on. How do I adjust to free up the lever a little?
Thanks, gregjo1948
Seasoned HDF Member
Joined: Aug 2009
Posts: 9,242
Likes: 3,262
From: west Michigan
Many TwinCam owners have learned the hard way that you need to follow the instructions in the Harley Davidson Service Manual when removing or installing the front brake light switch. I don't know if the Evos had the same setup.
I second the "Evo boards" recommendation.
I second the "Evo boards" recommendation.
Seasoned HDF Member
Joined: Apr 2012
Posts: 9,980
Likes: 5,218
From: Michigan
Before you continue, make sure that you have protective rags under your master cylinder reservoir, then turn the handlebars to get the master cylinder cover as level as possible. Carefully remove the cover and check to see that the fluid is at the proper fill level. If all is well, replace the cover and tighten the screws.
Loosen the clamp bolts that hold the brake lever/throttle to the handlebars and then push the brake lever assembly inward towards the master cylinder and then tighten the clamp bolts.
If this doesn't correct the problem you may be in need of a master cylinder rebuild.
I had this problem on a '96 RK that was just out of the factory but thankfully it was fixed under the extended warranty. I will admit that is used a small piece of folded paper, placed between the brake lever and the "plunger" that goes to the switch in the the master cylinder that activates the brake light until I could get my bike in for the repairs to be done.
Loosen the clamp bolts that hold the brake lever/throttle to the handlebars and then push the brake lever assembly inward towards the master cylinder and then tighten the clamp bolts.
If this doesn't correct the problem you may be in need of a master cylinder rebuild.
I had this problem on a '96 RK that was just out of the factory but thankfully it was fixed under the extended warranty. I will admit that is used a small piece of folded paper, placed between the brake lever and the "plunger" that goes to the switch in the the master cylinder that activates the brake light until I could get my bike in for the repairs to be done.
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