In Need of HELP Front Brakes Locking Down!!

[Archangel9599]

I have been a shadow around here for a while now, reading and learning. Well A few months ago after finishing up my project bike I pulled the trigger and bought a 2010 Raider and Immediately began making it mine reading these forms for advise. I have run into an issue that I cannot figure out though and its a serious one. I installed my ROX 3 inch extensions and a set of Kuryakyn Levers, (I did move my cables and hoses to behind the forks; and Bled the line{I thought}) took it for a spin and all seemed right in the world. Came home and the front brakes locked down, Brake lever is a stiff as a Viagra convention in Vegas. I rebled the brakes and all was good for about 45 miles. I have done this 4 or 5 times now WTH??? Anyone have any ideas of what I have screwed up? Thanks for the advise. 

[RoadStarRaider]

[Zekester]

If this condition did not exist before you did the work on the Raider then you need to backtrack what you did.  Sounds to me like your master cylinder is not releasing but instead pumping up pressure every time you use the front brakes.  Did you do anything with the front calipers when you were working on the bike besides bleed them?  If not I go back to the master cylinder or lever for freeplay.   How did you bleed the system?  Good luck.

[A.T.]

Maybe too much fluid in the reservoir?  The fluid expands when heated and would cause brakes to drag thus exacerbating the issue.  Or, assuming you didn't mess with the pads, maybe the master cylinder isn't releasing.

[sundancer87]

When the brake is applied and the lever gets hard there is back pressure there.  Something is keeping the fluid from going back into the master cylinder.  Perhaps the brake hose is kinked and holding the fluid back.  Maybe a photo of the front end might help with a diagnosis.

[Zekester]

Did you compare the stock lever to the kuryakyn lever?  Maybe the new one is not letting the M/C piston retract.

[Archangel9599]

Thanks guys, Photos will be incoming in a little bit I moved Ghostrider to the Shop and the Widow back into the mancave in frustration. And I will also check out the Levers as well, pretty sure I took a good look at them to do a Visual match before installing them but I'll pull and Pic them as well. And there are no visible kinks in the lines they do have a lot more slack to them since moving them to the rear though.

[StrykerBilly]

Maybe too much fluid in the reservoir?  The fluid expands when heated and would cause brakes to drag thus exacerbating the issue.  Or, assuming you didn't mess with the pads, maybe the master cylinder isn't releasing.

This is often the culprit.  You need air in the reservoir and NOT in the lines...   I'd check this first and foremost.  After that, another quick visual test on the lines and kinking.  Remember to push down on forks to make sure you have enough line for normal travel...

[Archangel9599]

Had to break up the pics.

[Archangel9599]

And Last but not least.

[Dirtiegirtie]

Not sure if this is possible, but if it is it will be easy and will tell you a lot...

Get the brakes to lock up.
Push the brake lever forward - did the brakes release?
Remove the brake lever - did the brakes release?
Use a screwdriver to tap the plunger (where the lever normally presses) a few times to see if you can get it to more - did it release?

[Coldfinger]

Air in the calipers will expand as it warms, locking the brakes.  Not saying that is your issue, but something it could be.  Any sponginess at the lever may indicate air in the system. 

[A.T.]

Not sure if this is possible, but if it is it will be easy and will tell you a lot...

Get the brakes to lock up.
Push the brake lever forward - did the brakes release?
Remove the brake lever - did the brakes release?
Use a screwdriver to tap the plunger (where the lever normally presses) a few times to see if you can get it to more - did it release?

Agree - sounds like the master cylinder plunger isn't releasing

[Archangel9599]

Well all I think we may have success; fingers are crossed. I took a bit of everyone's advise and began working backwards. And yes I am pretty sure the Kury Lever was the main culprit not allowing the master cylinders plunger to fully seat and close when not in use.  After taking every measurement you can imagine with my calipers they do no match a single angle on our stock levers at all. So out came to OEM and the dermal tool to do a bit of clean up and polishing and then a syringe to take a little bit of excess fluid out of the master cylinder and so far so good. Had a lot going on today so only could get out for about 20 miles but it felt good and no lock up knock on wood!! Thank you again for all the suggestions and advise this forum has saved another one!!   

[Archangel9599]

Little funny looking for side to side but it works now!

[Zekester]

Glad you found the problem,  hope you get a good ride in today to check it out.