Front brake issues
Thread Starter
|
Road Captain
Joined: Apr 2010
Posts: 671
Likes: 159
Front brake issues
So the last couple of weeks my front brakes on my 04 Road King went from being soft to almost completely dead. I bled the system a couple of times and finally flushed it completely and it still has the same issue. I can pump the front brake handle and it works great but once I ride a couple of feet it goes all the way down to the grip unless I pump it back up again.
Took it to the dealership today and they bled the system and still has the same issue. It feels a little bit better but they said they think I need a new master cylinder and new brake lines plus they wanted to pull and clean the calipers. $600 worth of parts and labor.
I'm thinking about just buying a master cylinder rebuild kit and either stainless front lines or just going with the stock black lines and cleaning out the calipers myself. Maybe $150 worth of parts and free labor.
Anyone else have any ideas or suggestions? I read up on turning the handlebars and holding the lever tight all night and then tapping the master cylinder but I just saw that suggestion today so maybe tonight I can try it. Otherwise I have flushed the system and tried to bleed it normally and with a vacuum bleeder.
Took it to the dealership today and they bled the system and still has the same issue. It feels a little bit better but they said they think I need a new master cylinder and new brake lines plus they wanted to pull and clean the calipers. $600 worth of parts and labor.
I'm thinking about just buying a master cylinder rebuild kit and either stainless front lines or just going with the stock black lines and cleaning out the calipers myself. Maybe $150 worth of parts and free labor.
Anyone else have any ideas or suggestions? I read up on turning the handlebars and holding the lever tight all night and then tapping the master cylinder but I just saw that suggestion today so maybe tonight I can try it. Otherwise I have flushed the system and tried to bleed it normally and with a vacuum bleeder.
Road Warrior
Joined: Apr 2010
Posts: 1,648
Likes: 37
From: Monroe, Louisiana
The master cylinder is by passing the fluid. You need a new master cylinder. If it still feels soft after new Master cylinder I would replace the brake lines. The calipers will make the brakes stick and not work or will drag. Brake fluid is an excellent paint stripper also.
Cruiser
Joined: Aug 2012
Posts: 158
Likes: 5
From: SC
For a couple hundred bucks, you can upgrade the entire brake system to the '08 brembo set up. MC, lines, calipers, and rotors from here or ebay should only set you back $300 or so if you shop around.
I just did this to my '03EGC and highly recommend it!
I just did this to my '03EGC and highly recommend it!
Road Captain
Joined: Sep 2007
Posts: 500
Likes: 2
From: Springfield Ohio
The master cylinder is by passing the fluid. You need a new master cylinder. If it still feels soft after new Master cylinder I would replace the brake lines. The calipers will make the brakes stick and not work or will drag. Brake fluid is an excellent paint stripper also.
Brake lines expanding when you apply the brakes will make them feel spongy. If you aren't losing fluid, the master cylinder is almost certainly the cause of your brakes losing that much lever (pedal). Flushing can't always get all the gunk out and, of course, can't do anything for a worn out or damaged seal. If you rebuild your own cylinder and calipers, make sure you inspect the walls closely to make sure there is no pitting or hard deposits that could render your efforts pointless. When you are done and happy with the results, consider doing the rear as well. It has been through all the same miles as the front and is likely in the same condition.
Thread Starter
|
Road Captain
Joined: Apr 2010
Posts: 671
Likes: 159
Brake lines expanding when you apply the brakes will make them feel spongy. If you aren't losing fluid, the master cylinder is almost certainly the cause of your brakes losing that much lever (pedal). Flushing can't always get all the gunk out and, of course, can't do anything for a worn out or damaged seal. If you rebuild your own cylinder and calipers, make sure you inspect the walls closely to make sure there is no pitting or hard deposits that could render your efforts pointless. When you are done and happy with the results, consider doing the rear as well. It has been through all the same miles as the front and is likely in the same condition.
I wouldn't say I'm going 'cheap' with buying a rebuild kit and new lines. Certainly will save money but that's being smart and not cheap. Getting a cheap product that isn't the same quality as OEM is way different than a rebuild kit and better lines. I'm 100% sure a good rebuild kit is as good if not better than stock as long as it's done right. Stainless lines are always going to be better than the stock rubber as well. I'm comfortable doing my own work correctly and saving some money as well.
Extreme HDF Member
Joined: Apr 2006
Posts: 10,449
Likes: 46
From: Roswell, GA
What often happens is the caliper pistons can't move freely due to crud building up so it takes more pressure to move them causing more m/c wear and swelling of the rubber lines.
So for sure you should get the HD caliper rebuild kit, replace the lines and rebuild the m/c.
Now, if you want a dramatic increase in braking power, do a complete Brembo swap.
Carl
So for sure you should get the HD caliper rebuild kit, replace the lines and rebuild the m/c.
Now, if you want a dramatic increase in braking power, do a complete Brembo swap.
Carl
Trending Topics
Extreme HDF Member
Joined: Apr 2006
Posts: 10,449
Likes: 46
From: Roswell, GA
Also, there is a minimum thickness sped embossed in the rotors. Confirm that your rotor thickness is okay.
Carl
Carl
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Southpaw Super Glide: A Left-Hand-Drive 1979 Harley FXE Built to Fit the Rider
Verdad Gallardo
The Best and Worst Harley-Davidson Moves of 2025
Verdad Gallardo
Thread Starter
|
Road Captain
Joined: Apr 2010
Posts: 671
Likes: 159
Rotors look almost brand new. Bike only has about 20k miles but I am very surprised how well the rotors are doing. The front pads where recently replaced at the dealership so everything should be doing alright. Hopefully they would of cleaned them out a little or told me they looked bad but if the master cylinder rebuild doesn't fix it I'm going with new lines and trying to clean or rebuild the calipers.
