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Front brake lever, excessive play

Does seem that a rebuild kit would be your next step
Be aware that sometimes in the UK the wrong brake fluid may have been used as dot 5 is not common and some people will use whatever they can get
silicone based dot5 and glycol based dot4 do not like each other and should never be mixed
Get the correct fluid from the dealer

Brian
 
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Thanks Brian...yes I already got a small bottle of EBC dot 5 which I used to fill the cylinder a couple of weeks ago after removing all the black crud from inside it, so as you say, it was probably not filled with DOT 5 on its last 'service'!
I had read up about the difference...all a learning curve.
so next project.....rebuild kit...
 
It is not a big job to do a master cylinder rebuild just ensure you take good care on draining the system as if there is any glycol based fluid still in there and it gets on the paint it will bubble and strip the paint off
It can take a wee nudge to get the old parts out of the master cylinder but as they are heading for the bin anyway
With the master cylinder on the bench I use a suitable sized allen key in where the banjo bolt fits push on to the piston inside and tap the end with a mallet and it all pops out take note of the order and orientation of the old parts as they come out clean everything and fit the new parts

Brian
 
fin_676 said:
It is not a big job to do a master cylinder rebuild just ensure you take good care on draining the system as if there is any glycol based fluid still in there and it gets on the paint it will bubble and strip the paint off
It can take a wee nudge to get the old parts out of the master cylinder but as they are heading for the bin anyway
With the master cylinder on the bench I use a suitable sized allen key in where the banjo bolt fits push on to the piston inside and tap the end with a mallet and it all pops out take note of the order and orientation of the old parts as they come out clean everything and fit the new parts

Brian
Click to expand...

Brian is on the money here with great advice. Regarding his comments on protecting the paint from the brake fluid, that is no joke. I use a combination of a heavy gauge plastic drop cloth and my old car fender covers for added protection of my gas tank and fender. This way the paint is protected from the fluid, wrench or other item that becomes a variable of Murphy's Law. Enjoy the new ride and keep her looking sharp.
 
My 99 Ultra had the same problem. I put a spring inside the housing to push the lever out. Works great.

Toby
 
Thanks again guys, all this advice...and for my first post on here!
I checked if a local specialist has the part in, so will be picking it up Saturday morning, I have a new bottle of EBC Dot 5, a new front brake light switch...so all set to go!
Cheers Ian
 
...just an update, removed the fluid ....then took off the banjo bolt....gave it a couple of squeezes and the push rod...popped out and back to its correct place, ...so decided to leave it and fit the new brake light switch and see how it goes....so far all ok!
 
Possibly been some dirt on the seals and with the banjo bolt off the dirt got expelled however I would worry a wee bit about the integrity of the seals and be prepared to do the master cylinder rebuild in the near future

Brian
 
Hi Brian....I had that thought at the back of my mind, the lever was back in its correct place, with a good feel on the spring, but after a couple of runs out and my new front brake light switch is coming on when it shouldnt...hence a little more play in the lever again!.....its a learning curve.....cheers!
 
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