I need to check oring on plunger in handlebar brake assembley.had no frt brakes when i was going for 1st ride..took cap off all fluid had jelled!.air pressured it all out.cleaned it up..seems like a oring prob...any suggestions ,thoughts? please!! and tyvm!

 

My recommendations after fighting brake problems for many, many, years.

Get yourself a bottle of DOT 5 brake fluid, a caliper rebuild kit, new pads, master cylinder rebuild kit, and a new gasket for the master cylinder cover. You don't care if the manual, master cylinder, or the guy at the shop says your bike takes DOT 3, you're going high-tech with DOT 5 from this point forward.

Ok; very carefully clean and rebuild the master cylinder and caliper. Clean out both holes to make sure they aren't blocked. Run a small cylinder hone in the master cylinder bore too. Look for pitting and scratches. If it is still pitted after honing, get a new one. Don't forget to squirt a healthy does of brake cleaner through your brake line to clean it too. This after you've inspected it for cracks and determined that it doesn't need replacing.

Also check the rotor for wear and possible warping. Be careful with that little switch in the master cylinder. If you try and take it out, it will easily break. It is probably stuck in place with crystalized DOT 3 fluid.

Put it all back together using DOT 5 fluid on all moving parts and rubber stuff, bleed, and enjoy. Lightly grease the caliper pins, lever hinge point, and the plunger end.

Now that it is all done you have completely rebuilt your front braking system and it should give you years of trouble free operation with only minimal maintenance.

Welcome to the forum.

Carl

 

Thanks so much Carl! sounds good and simple enough..

 

+1 on Carl's info.

IronHeads were DOT 5 from the beginning and that never changed. Anyone who suggests otherwise is just plain wrong wrong wrong.