I changed my front brake lever the other day and thought it was a simple as simply swapping over levers.  It was pretty sraight forward out with the pin, in with new lever and replace pin simple, or so I thought.  Went for a ride and about 4 klm up the road and I has gotten hot, I knew something was up as it started slowing the bike down, by the time I made it home there is hardly any pads left and the rotor is blue.  Should have I cracked the bleed screw after fitting new lever?

Cheers

The new levers must have been applying pressure to the master cylinder as soon as you fitted them.
I doupt if cracking the bleed would have done anything.

The levers only push against the piston in the master cylinder and when not applied there should be a gap between lever and piston.

Did you notice if the new levers were tight when re assembling?
Was there any free play in the lever after assembly (or even now)?

Hi Nomada,

Not any real free play as I noticed, I will pull it out and check it for size against the old one, viually looked the same but I will measure it. It's a no name brand replacement, might bite me on the arse.

Unless its a genuine HD lever, I can guarantee there will be minute differences. Casting diffs hard to pick up by eye. Has caused the brakes to apply and does not release them fully. Not a problem though, out with the dremel. Happenned to me. First pair I tried to tap but only soft alloy and cracked them.

Cheers

Thanks Steelo, I will have a look.

Hi there.

I've taken some pics for you. I bought some nice chromed levers after I broke the end off my originals. They caused the brakes to seize. No play at all. Couldn't see any difference. Use the dremel to slowly machine away the following surfaces. Doing this is designed to actually make space for the brakes to release. Take your time. I also used the existing lever bush for the pin. They work a treat now and look good to boot.

Cheers.

 

 

Steelo, you are a legend! Thanks mate, I will get onto it, I have since put the stock lever back in.

Im guessing the original lever dosent give you any probs then?

That is correct. I will attack my replacement lever with my die grinder and see what happens.