I know I need rotors. They pulse a little when I stop. I'll do new pads at the same time. But recently I can pull the front lever all the way in. No leaks I can find and the level of the fluid is good. Anything else I should/could do while I'm at it? It's a 2003 FLHRCI.

Michael

 

Sounds like a bad master cylinder to me.

 

Pull the caliper off and clean the pistons.

 

I have a service manual. If I feel I can do it safely, I will. I'll also be ready to replace the master if needed.
If I do change it, do I go with the 2003 one? Or are newer ones better and still a direct replacement?
Stopping well is more important than anything, IMHO.

 

It's happened to me already few times with my two last Fatboy (2006 and 2008).
Check if you have enough break fluid in the reservoir (I saw you checked), check if no bubbles in the circuit.

I had the problem when I was driving down a big slope. I guess if the break fluid level is to low then you loose the rear break. Here in Mexico sometime it is very very hot and I know I have to check fluid level during all the big trips.

Regards

 

Warped rotors that pulsate will cause your brake pads to cavitate. That is they will move in and out at a rapid rate which can and often does result in air being pumped into the system past the seals. When Air gets into the system you will get a low or spongy lever/pedal. Because you state your brakes pulsate this could be your problem. You can try to bleed the front brakes to see if there is any air present. If there is you will get a good lever again but you can rest assured that after a short ride you will experience the exact same symptoms until you correct the rotors. This is a very common problem with the C2 and C3 Corvettes when the original rivited rotors have excessive run out and are out of spec. I've had this happen on my Corvette a few times over the 20 plus years I've had it. Good luck....

 

bleed the brakes

 

Pull the lever in and hold it on a cable tie. Leave it over night the pump the lever the next day. Any bubbles in the lines will perculate up into the reservoir.

 

That would be my suggestion as well.

 

If you haven't fflushed the brake fluid, now is the time. Replace the brake pads and see if the brake lever still comes all the way back to the grip. I'll bet it won't. lf the rotors are warped, replace them. There's no excuse for riding a bike with bad brakes.