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Tucson_Tim
14th March 2006, 23:55
04 1200R with 6.5K miles...

The brake lever vibrates a lot when idling and I just noticed that it doesn't go back far enough to turn off the brake light - so brake light is always on. Front brake is slightly mushy but not too bad.

I've searched and found a few threads that address this problem. Some solved the problem by just bleeding the front brake fluid; others had the master cylinder replaced.

I have the service manual. I have adequate tools and pretty handy with them - by no means Mr. Goodwrench though. Is it a tough job to replace the top master cylinder?

Tim
Everett
15th March 2006, 00:00
on my 88 xlh, in the housing of the front brake there is a little metal strip i guess i would call it, that presses in when the front brake lever is pulled in to trigger the brake light. it was sticking or bent a bit, so i opened it up and bent it a bit and now it doesnt stick but still good enough to light up the brake light when i pull in the front brake.

hope this helps in some way. maybe its not though.
whispanic
15th March 2006, 00:03
http://www.xlforum.net/vbportal/forums/showthread.php?p=316268#post316268
Chuck
15th March 2006, 00:43
It's not that hard. If it's the mc just buy a rebuild kit for $15. I had the same symptoms, loose lever, light coming on. Make sure it's not the switch though. Make sure you use the correct brake fluid.
Tucson_Tim
15th March 2006, 01:15
I've looked thru several old threads here and I've looked thru the service manual and parts manual and I think it needs the rebuild kit part # 42809-04, which comes with a new spring. I think this is what is failing - not pushing the brake lever back far enough to turn off the brake light.

Dumb question: Can I get the DOT5 brake fluid at any auto parts store?

Tim
IronMick
15th March 2006, 01:53
... Can I get the DOT5 brake fluid at any auto parts store? ...

Yes. Yes. Yes.
Tucson_Tim
15th March 2006, 01:59
Another question: The manual suggests attaching plastic tubing when draining/bleeding. Anyone know what diameter plastic tubing? I was just going to buy several pieces, several feet long, of various diameters at the auto parts store...
xl1200r
15th March 2006, 15:27
Tim,

This should be covered by your warranty if it hasn't run out yet. A rebuild will fix the problem.
smoke
15th March 2006, 15:40
Tim,

While you are at, I would use speedbleeders (http://speedbleeder.zoovy.com/) and their $6.00 kit with the tubing and IV bag (both reusable). I used it when I changed out my bars, cables, and brake lines and it made it an easy task of brake bleeding even easier. Good luck! I have never changed the front master cyl, but it looks easy enough. Even for a Mr. Dumbwrench like me.
Tucson_Tim
15th March 2006, 15:44
Tim,

This should be covered by your warranty if it hasn't run out yet. A rebuild will fix the problem.

Warranty expired... Will attempt the rebuild...
Tucson_Tim
15th March 2006, 15:47
Tim,

While you are at, I would use speedbleeders (http://speedbleeder.zoovy.com/) and their $6.00 kit with the tubing and IV bag (both reusable). I used it when I changed out my bars, cables, and brake lines and it made it an easy task of brake bleeding even easier. Good luck! I have never changed the front master cyl, but it looks easy enough. Even for a Mr. Dumbwrench like me.

Thanks for the link - definitely going to get one. Did you get it from their website or is it available at an auto parts store? Or some clone?

Tim
Tucson_Tim
15th March 2006, 15:49
Good luck! I have never changed the front master cyl, but it looks easy enough. Even for a Mr. Dumbwrench like me.

If there's a way to screw it up, I'll find it! :p :doh
Tucson_Tim
3rd April 2006, 21:56
Rebuilt my front brake master cylinder today (see other thread in this section).

Problem solved!!!! :smoke :tour :banana