2 weeks ago I get the 1000 mile service and on the test ride the rear brakes lock up on the HD mechanic. The caliper and the rotor are toast--literally, the rotor turned blue and the caliper cracked. The dealership tells me they will replace anything damaged. Great. I get the bike back today from the Dealer and on the way back home same **** happens to me--it locks up, but the wheel will turn in gear. I guess the best way to describe it would be applied brakes at 75%. I rode it like that 50 yards or so to the nearest gas station and the rear started to smoke. Great---what can it be?

 

I've never heard of such a thing. Lucky it wasn't the front break....I know you don't have a Gold Wing so it can't be an ABS pump going crazy. It is a mechanical motion that has to set that in place. i.e. break pedal as you know. I have no idea on what might be causing that but I sure want to hear the fix....Since the rotor and caliper are messed up I guess it's not the wheel bearings??????

 

Sticking twice? .... maybe a blockage in the fluid line or the mastercylinder hanging up. A poor fitting piston in the master cylinder may not be releasing fully and keeping pressure on the puck. I might suggest the dealer replace every thing from the pedal on back; mastercylinder, hoses, lines, caliper, mounting hardware (heat may have weakened the bolts) and rotor just to be sure......Just my thoughts.....

 

Got it back today. They are telling me it might be the heat from a heat shield. They modified a few things and it seems better now, but I dont know if I trust this. Can replacing a master cylinder cap,--one of those chrome ones,--put air in the line and cause this? I replaced one right before that happened the first time but nowhere in the instructions did it say to bleed anything. Anyone?

 

yes the cap does matter and the chrome aftermarket are crap.