im working on a 2004 ultra ,the owner installed a new set of front pads.a short time after that he looses his front brake.the brake lever is so soft it touches the grips. we tried bleeding to no avail and just replaced the master cylinder and we have the same problem. i bled them with a mity vac pump and by hand. i dont see air in the line thats the problem.has anyone had a similar problem the front brakes are working they will lock up the wheel when the lever is squeezed its just such a soft lever thankyou for any advice

 

Anyone have any suggestions

 

I believe at some point the pistons have to be cleaned of debris so the can return in the bore. Maybe when he put the new pads in the debris is holding them up? I think there is something like this in the repair manual. FWIW.

 

Did you bleed the master cylinder? If not you need to. pump the breaks and crack the break line loose a small amount at the master. you should see a few bubbles.

 

Also make sure you are using the right break fluid.
I know just want to cover all bases.

 

I am 99 percent sure that you only need to clean your calipers. This is a common problem for Harley touring bikes up to 2007.

Pull off your calipers and Extend the pads. Then liberally use a can of brake cleaner all around the pistons. You will see a lot of dirt drip from the caliper, so protect your wheel and fender with a towell or blanket. Compress the pistons all the way in the caliper and clean again. Then extend the pistons and clean again. You should notice a big difference. I had to clean my calipers every 3000 miles with stock Harley pads and every 10000 miles with Lyndall pads.

Lyndall explains this proceedure on their Web Site.

http://www.lyndallracingbrakes.com/service_tech.htm

Beary

 

You say he LOOSES his front brake, but then say it will lock up the wheel, but just feels soft. If it will lock up the wheel, he isn't loosing the brakes. My 04 ultra has a soft feeling brake lever. Always has. Sitting still, I can squeeze the lever all the way to the grip. When riding, the brake functions fine and will lock up the wheel easily. At first, I assumed it needed bleeding because it felt spongy. Bled it sevral times and no change in the feel, but always functions properly. I know in the old days, car brakes needed to be bled until the pedal was rock hard, but all the modern cars I drive do have a spongy feel to the brake pedal even when properly bled. (My dyna and my wife's sportster all feel the same as the ultra, and all work fine.)

 

caliper pistons are dirty....clean with brake cleaner good

 

Do you have to replace the pads everytime you clean the calipers?

 

No; but, Lyndal's website procedure is doing the piston cleaning in conjunction with the installation of new pads, and using the screwdriver to lever the pads/pistons to retract after cleaning may damage the pads. If the pads are being replaced because they're worn out, no problem if they are damaged.

An HD tech told me about this procedure and it felt like a "miracle," the reduction in brake lever travel was very dramatic.

Carl

PS: Using stainless brake lines also helps overcome sticking pistons; the OEM rubber lines simply swell with the increased lever travel and the increased volume of brake fluid pushed into the lines while the stainless lines don't swell nearly as much.