Hey Guys,
Some a**wipe decided to push my bike on the ground >:( while it was parked and I have been having some issues since then. Thanks to the posts from all the experienced members here, I know the solution to the problem of the starter motor turning without turning over the engine. However, I noticed another problem. My brake light stays on continuously. I isolated the problem to the front brake lever not compressing the switch below it in its unactuated position. I tried removing the front brake lever, but don't see any way to adjust the distance between the brake lever and the switch to correct this problem. Another possible solution seems to be somehow adjusting the relative distance between the brake fluid reservoir and the brake lever. But I don't know of a way to do that. Has anybody experienced a similar problem before? If yes, any advice on how I should go about fixing it?
Thanks,
Tushar
Pictures?
Sounds like your brake lever or the mounting was damaged. Everything is supposed to fit just fine with no adjustments necessary. With things not fitting, one of them is damaged.
Most likely just the lever is bent. Order a replacement from MotionPro (their levers are really good quality and not very expensive) or post a want-to-buy because probably people on the board have extra levers.
Thanks for your input. I have attached a picture. I thought that part of the lever is fairly strong for it to bend and it didn't look bent when I had taken it out. If you look at the picture, the brake lever doesn't return back to its original position (where the front surface of the lever is flush with the front surface of the triangular extension of the brake fluid reservoir).
(https://lh5.googleusercontent.com/-_2uUpmXa3RU/UPoigiDArVI/AAAAAAAAG54/JRDydUaG19Q/s640/IMG_20130118_204656.jpg)
One thing to do is lube it up. It looks somewhat corroded. Remove the lever. Clean and grease the pivot and a dab where it presses on the master cylinder. Put back in. Do not over tighten. Rely on the lock nut to keep the bolt in and use thread lock.
Most likely it or the mount got tweaked. Lubing it should make it move freely again.
The master cylinder is the spring that pushes the lever back. Possibly the plunger in the MS is gummy. How long since the brake fluid was changed?
I tried following your instructions. But that doesn't seem to be help. I also took a picture of the removed lever attached below. It doesn't look bent to me. Do you think otherwise? I don't remember exactly but I think I changed the brake fluid about a year back when I changed my brake pads. I am assuming you think the brake fluid level might be low for some reason? I didn't see any lowering of the brake fluid level in the brake fluid reservoir whenever I have changed brake fluid in the past. So don't think it would be a likely problem. But I will check soon. Unfortunately the reservoir screws are heavily corroded. So need to get replacements before I open it. Anything else you feel might be wrong?
By the way didn't realize earlier that you are the guy from some of the videos on youtube regarding gs500 maintenance and upgrades that I have been watching! Thanks for posting those videos, they have been very helpful :thumb:
Tushar
(https://lh3.googleusercontent.com/-KkrdfdVYusc/UPs_V2EMh-I/AAAAAAAAG6g/wnauAwB8ooo/s640/2013-01-19%252016.56.08.jpg)
Lever looks OK.
Does it move freely when mounted with the bolt loose?
There are no adjustments so only things I can think of now are:
1. Screws holding in brake switch loose or missing so it is not positioned correctly
2. master cylinder piston is gummed up or the internal spring is broken
The master cylinder piston is what pushes the lever back out causing it to press down on the brake switch.
If the lever is sticky, it won't return all the way out.
If the master cylinder piston is gummy (why I asked how old the fluid was) it can get stuck and not push back on the brake lever.
If the internal spring in the master cylinder broke, it won't push back out on the lever.
If lever is sticky and you push the lever back out so it presses on the brake switch, there should be maybe 1/8" of play when pulling the brake lever in before it presses on the master cylinder piston. If there is lots of movement before it contacts the master cylinder piston, then probably the piston is stuck or spring broken.
Also possible that something got damaged from falling over. There appears to be a tiny bit of rash on the end of the lever.
You can get replacements for $15+p&h on ebay from Pinwall Cycles and others. Go for a late model bike. All are the same. I would say get a replacement rather than rebuilding it because replacements will be newer and cheaper than a rebuild kit. Plus it is a no brainer no work solution - just drain fluid. Put on replacement. Add fluid.