Was curled up with my Dyna shop manual last night (get a life) when I came across an interesting sentence buried in the section on front brake calipers. "Do not lube piston seals and wipers with brake fluid, use only GM Silicon Grease or you will experience excessive lever travel."

This would seem to support the opinion that at least some of the excessive lever travel is due to pistons sticking in caliper bores.

 

The Harley caliper repair kit comes with packets of grease.

 

Sleepless nights are hell when all you have left to read is your shop manual!

Do you actually suffer from excessive lever travel? There are other possible causes, which we can discuss if necessary.

 

Hi,
Just bought an 02 Ultra Classic with 8K miles and I find that the front brakes only start to grab after pulling in the brake lever about half way. Immediately bought a container of Dot 5 figuring the level would be low but when I uncapped the reservoir it was right up to the top. Just joined this forum also, and it appears that this is a common problem with multiple remedies (?) Help! I like brakes - that work!!

 

Did the world wide web stop working after the previous post? I have the same problem with my '03 FLHTCUI .... front brake lever won't engage the brake pads until pulled halfway. Fluid level is fine. Bled the lines, no air. I'm suspicious of worn pads. Bike has 30K and maybe the original pads?

 

Hydraulic brakes compensate for pad wear. Go to the Tech Brakes section where you will find a Sticky about soft front brakes. Hopefully it will help you solve your problem.

 

Thanks Mr. Brown. I have re-directed to that sticky!