Hawk 250 front brake lever issue

[Redbookaudio]

Hi all,
I’m new to this sight (and blogs) and new to motorcycles. My daughter just got a Hawk250 and we’ve enjoyed putting it together (learning a lot!) The front brakes work great (we changed out the brake fluid and bled air out of the line.)
The issue is that the front brake lever doesn’t return all the way out when released. It’s not applying the front brakes when it’s released, but it’s also not engaging the little black switch that turns off the brake light. So we ride around with the brake light on unless we physically push the brake lever the last 1/8” out. Thanks for any help on this issue! Chuck

[Megadan]

Well, before we go diving into more complicated possible causes and solutions, let's start with something simple.

I would remove the lever and clean up and apply a little waterproof grease to the shank of the lever pivot/mount bolt as well as any contact surfaces where it mounts to the master cylinder.

To remove the lever you will need a flat head screwdriver and (if I remember correctly) a 10mm wrench. It will be the only big flat head screw located right where the lever pivots. On the underside of that screw is a nut. Loosen and remove the nut first, then remove the pivot/mount screw.

When you re-install the pivot bolt and the nut, just make sure you don't go to town tightening them back down or you run the risk of potentially breaking things or stripping threads. A little loctite on the threads goes a long way.

Once you try that, see how it behaves. If it is still hanging up, it is possible that you got a defective master cylinder.

[JerryHawk250]

Originally Posted by megadan

well, before we go diving into more complicated possible causes and solutions, let's start with something simple.

I would remove the lever and clean up and apply a little waterproof grease to the shank of the lever pivot/mount bolt as well as any contact surfaces where it mounts to the master cylinder.

To remove the lever you will need a flat head screwdriver and (if i remember correctly) a 10mm wrench. It will be the only big flat head screw located right where the lever pivots. On the underside of that screw is a nut. Loosen and remove the nut first, then remove the pivot/mount screw.

When you re-install the pivot bolt and the nut, just make sure you don't go to town tightening them back down or you run the risk of potentially breaking things or stripping threads. A little loctite on the threads goes a long way.

Once you try that, see how it behaves. If it is still hanging up, it is possible that you got a defective master cylinder.

^^ 2x^^

[Redbookaudio]

I’m happy to try what you guys are suggesting, but I don’t think I explained the issue accurately. We have removed and inspected the brake lever numerous times and it seems fine. It is not “hanging up”, it simply seems to flop around (or have “play” in it) the last fraction of an inch before being fully opened or released to the front where it will
(would) engage the small brake light switch. Gravity seems to be keeping it from engaging the switch, or perhaps if the brake cable could somehow be adjusted to push the lever out a fraction further? Idk... does this make sense. It was working when we first installed it.
Do you have a favorite waterproof grease we should get? Sorry, I warned you that my daughter and I are NEW to this stuff!��

[pete]

since it is not sticking try
removeing a bit of the free play from the clutch cable..

check that the brake light switch is fully pushed in to its
fitting in the lever perch..


.

[Megadan]

Yeah, so now I am confused so I want to clarify something. Pete already kind of touched on it, but you say brake, but then mention a cable. Is this the lever on the left or the right (as you are sitting on the bike)?

[pete]

Originally Posted by Megadan

Yeah, so now I am confused so I want to clarify something. Pete already kind of touched on it, but you say brake, but then mention a cable. Is this the lever on the left or the right (as you are sitting on the bike)?

Yes ... very good point.......

forget my earlyer post..... had a moments brain fade....

some brake levers do have a small return spring....




.

[blanc12]

Try to loosen the nut on the brake lever. It uses a lock nut and bolt to hold it in place. If you have it too tight it may keep the lever from coming all the way back. If the ears are bent you may have to move it in and out some to loosen it up. This lever return is caused by the master cylinder spring inside the master cylinder.

[Redbookaudio]

Sorry I misspoke using the term “cable” on a brake lever... ooops! Its more like a hydraulic line, right? I do know that the lever on the right is the front brake lever (and the left lever is the clutch...)
We got a new brake lever sent to us (free) from TXPowersports where we got the bike from, and replaced the old one. No change. If there is a way to adjust the brake line which would push out the plunger, or whatever the part is called that the brake lever pushes in on when squeezed (is that the master cylinder?) that would make the lever return fully and engage the brake light switch.... otherwise we are stumped... Meanwhile perhaps my daughter and i need to read up on “the anatomy of a motorcycle front brake system!”

[JerryHawk250]

It would probably be best to replace it. Apparently there is something keeping the plunger from returning al the way. May be a bad spring. I don't have my bike in front of me but I don't remember seeing anyway you can adjust it. Glad TXposwersports took care of it. If they would be consistent with all there customer they would be good to deal with.
Check to see if there is room for adjustment on the switch.

[Redbookaudio]

Thanks JerryHawk....great picture of the brake light switch. We've had that off and on 5 times hoping it could be adjusted, but it only goes on ONE way (into a hole etc...) And the brake lever is totally free from and connection to anything.... it simply pivots pressing in on the plunger, or when it returns it engages the brake light switch, turning off the brake light. Our brake lever will engage the switch if we give it the slightest pressure but as soon as we let go of the brake lever it flops back a fraction and disengages the switch.

[Redbookaudio]

Megadan, from the comments below you’ll see that ive replaced the brake lever with a new one... no change. What are your thoughts on the “defective master cylinder.” Should we just go ahead and install a new front brake system? Thanks for all the help you give to so many folks in the motorcycle world!

[Redbookaudio]

Ha! I guess the comments are above!��

[Megadan]

Yep, you found it already in the other comments, but that master cylinder is likely the culprit. Either a bad spring, or the piston or a seal is hanging it up and not allowing it to return that last little bit.

[Redbookaudio]

Thanks Megadan.... we’ve contacted TXPowersports to see if they’ll send another front brake master cylinder.