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

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Tags
brake caliper, brake lever, disc brakes, sportster 1200

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  #1  
Old 21st November 2017
Sportster-92 Sportster-92 is offline
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Sportster/Buell Model: sportster XLH 1200
Sportster/Buell Year: 92
Reputation: 819
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Default Front brake single piston problem

Hey guys I have been having this really annoying issue with my front single piston floating calliper brake system on my 92 sportster where the brakes drag hard. I get a 1/2 turn if lucky and get constant high pitch noise when riding the bike all the time. I also have too much play up at the lever.

I drained the system, pushed out the piston and cleaned out the whole calliper. noticed a few light marking on one side of the piston but nothing major and there was no scoring. The seal looked good inside so left in.

Fitted a rebuild kit to the master cylinder and before filling up with dot 5 the lever play had completely gone. So the spring must be pushing the lever back correctly. After filling and bleeding it was just as before with the brakes hard on and the same amount of lever play.

Its driving me crazy now.

Any suggestions would be great.

Cheers.
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  #2  
Old 21st November 2017
hotrodbiker hotrodbiker is offline
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Hi again ! I ve never had this occur on a bike but if you ve got the original rubber brake hose they can break down inside and allow fluid to put your brake on but not return ,just a thought , I have had this happen to my old Jeep and new lines fixed it
hope this helps
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  #3  
Old 21st November 2017
Sportster-92 Sportster-92 is offline
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Sportster/Buell Model: sportster XLH 1200
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Cheers Hotrodbiker its actually got a stainless hose thats not that old by the look of it.
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  #4  
Old 21st November 2017
hotrodbiker hotrodbiker is offline
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Default

ahhh wont be that then ..damn ! Hopefully someone else can help you out , I cant think of anything that would cause drag and a sloppy lever ...with the brake dragging so much do you think it may have heated the disc and warped it ?
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  #5  
Old 21st November 2017
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juzyHD juzyHD is offline
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Default

What about the other side of the caliper? Does it moves freely?
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  #6  
Old 21st November 2017
Sportster-92 Sportster-92 is offline
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I doubt the disc is warped but will check it out when I strip the mag wheels when I convert to the spoked. It looks like I am going to have to replace the piston and seal on the calliper. It didn't look to bad, its the only thing that I can think of that might affect the system. Its like the pistons won't return back in after the lever has been released.
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  #7  
Old 21st November 2017
Sportster-92 Sportster-92 is offline
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Hi JuzyHD its a 92 calliper so it only has a piston on the one side.

Cheers.
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  #8  
Old 21st November 2017
Sportster-92 Sportster-92 is offline
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just realised I haven't mentioned its a single disc brake
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  #9  
Old 21st November 2017
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juzyHD juzyHD is offline
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Yes there is piston only on one side, but the other part should move freely. Otherwise you only get pressure on the left side of the disc. The part of the caliper that goes over the disc to the right side must move freely on the bolts. The housing of the caliper or how should I say...
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  #10  
Old 21st November 2017
Sportster-92 Sportster-92 is offline
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Thanks for the info Juzy the calliper does float correctly as I checked this and greased the bushing and mount pin. Its seems like the piston is pushing on the disc and sliding the calliper over as both pads are on the disc. Resulting in 1/2 a turn of the wheel by spinning it by hand and the lever does not return fully.

Cheers.
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