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Sportster Motorcycle Tires, Wheels, and Brakes Discuss issues with Sportster motorcycle tires, wheels and brakes.

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  #1  
Old 4 Weeks Ago
dgolino dgolino is offline
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Default Front brake lever

I have a 2002 sportster hugger seems like the front brake lever moves close to the grip when applied. Brake pads look good any ideas.
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  #2  
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RussW RussW is offline
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The mechanic at my local HD dealer gave me a tip for my 2002 Hugger; he said push the pistons back into the caliper by gentley slipping a screwdriver between the pads and disc, then pump the lever a few times to pump the pistons back out. Lever is now much further away from grip when brakes are applied. Worked for me....
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  #3  
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dgolino dgolino is offline
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Thx I'll give it a try
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  #4  
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on an '02, which brake fluid are you running? supposed to be DOT-5 not 3 or 2
if it's been mixed in the master cylinder it can cause this and a host of other issues
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hd does not use a squealer system to detect pad wear. they use loss of stroke. the pads will have plenty of material left. the pump up mentioned will only return to loss of stroke.
i DO NOT suggest this but since i always am on top of maintenance and regularly check my machine due to my ride style, i made pad shims to recoup the lost use of pad material. once i get to loss of stoke to my liking, i install the shims and run the pads till loss of stroke again and then install new pads, even so, plenty of pad material left.
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Probably time to do a brake fluid flush, anyway. Should be done, at least every 2 years,IMO.
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dgolino dgolino is offline
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Turns out had to replace the master cylinder
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Quote:
Originally Posted by dgolino View Post
Turns out had to replace the master cylinder
What exactly was wrong with the old one? Not rebuildable?

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was the master by-passing? only way to get loss of stroke from it.
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