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The adjuster on the upper brke lever is leaking brake fluid ?
I am trying to get the proper way to fix this leaking plunger on the adjuster? the adjuster is under the plastic cover and leaking ever time I pull the brake lever more than a few drops.
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usually the plungers at the brake caliber ,
but might be out of fluid, sometimes if system goes dry upper plunger at brake handle, might crack? wont push fluid
there are rebuild kits for both ends
could also be rusted in place?
There is no adjustment, either it works, or not. Usually, improper installation of the front master cylinder breaks off the little tab on the switch that the brake lever pushes against to turn the light off, though it could probably get worn down. Also, maybe some gunk is in there gumming up the plunger action of the switch.
Park brake lights normally operate by a small plunger type switch the turns off when the level or pedal is placed in the off position. Over time the spring in the lever weakens and placing the lever in the off position no longer depresses the switch. The switch can sometimes be adjusted to make better contact, or the switch bracket can be bent so the lever and switch make proper contact.
Do not despair, you have your work cut out for you but it is a relatively easy fix. Your brake master cylinders are dirty and plugged with rust. You will have to take apart and clean your brake master cylinders. Consider purchasing the rebuild kits and replacing all the rubber parts in the master cylinders and the caliper pistons. This will ensure you many trouble free years of operation in the future. If funds are tight a simple cleaning of the master cylinder reusing the old parts may suffice. When you rebuild your master cylinder you will need to look down the reservoir at the large brake fluid feeder hole. Right next to it is a tiny pin hole. That is the brake fluid return hole for the reservoir. It is probably plugged with rust or dirt. When it is plugged , if you drive a short distance and the wheel locks up. Open the bleeder screw to release a squirt of fluid and you can drive back home before it locks up again. Clean out the hole with a single straight bristle from a wire brush and see if that fixes the problem. You may not need to disassemble any thing to get the systems working properly but you will need to do a thorough bleeding to get all the debris out of the brake lines. This is a common problem on all older machines when the brake fluid is allowed to sit in the system for many years unchanged. Use only new DOT 3/4 brake fluid when refilling the reservoir. First , cover your cycle with plastic and a towel (brake fluid will damage your plastic and paint), remove your brake lever, remove the reservoir, use a clean lint free rag to soak up the fluid in the reservoir, grab the rubber cover that brake lever pushes on and gently pull it out (if it tears a new one comes in the kit from Honda). Using an internal snap ring pliers, remove the inner circlip, now you can remove the master cylinder plunger. Use the old plunger as a reference for putting the new rubber pieces on the metal plunger in the kit (it comes disassembled). Gently wipe out the inside of the master cylinder with a lint free cloth. DO NOT HONE OR SAND THE INSIDE OR YOU WILL RUIN THE CYLINDER. Make sure the pin hole is clear and reassemble. Loosen the banjo fitting for a couple of pumps while bleeding to get the air out of the master cylinder , this will make bleeding easier.
I will assume you have the hydraulic brakes and that is the fluid you are referring too.
If you have never done any hydraulic maintenance you will need a number of parts and tools to fix a leak, especially at the lever. The best solution would be too drop the bike off with your local mechanic/ bike shop and have them properly fix the system. After 5 years your lines and seals are most likely cracking and you need to replace the housing and seals at minimum + rebleed the brakes with the proper oil. Either way to tell you exactly what parts you need someone needs to see the bike. Take it into the shop as suggested already so they can at least tell you which seal kit and which bleed kit you need as well as the proper oil. you will need to buy all this from the shop anyway, ask them the cost difference between buying the parts and kits to do yourself and them doing the work for you.
Open your brake reservoir and check fluid level. Add fluid to proper level and slowly squeeze the lever, watching for bubbles or fluid flow in the reservoir. Check the brake calipers to ensure there is not a leak in that area. If no leaks, continue squeezing the brake until it is fully operational. May have to add fluid while doing this. Close reservoir.
for hydraulic brake systems, there is a little rubber seal on the plunger attached to the lever. This is part of the lever/reservior assembly. An older bike like this may be fixed cheaply by changing it. If your reservior level is low, then it could simply be needing fluid. first try bleeding the brake lines of air. If that does not do it, then check bikebandit.com for the plunger.
Using a brake tool, remove the shoe return springs.
Remove the shoe guide.
Remove the hold-down springs and pins.
Remove the actuator lever and pivot.
Remove the lever return spring.
Remove the actuator link, parking brake strut, spring retaining ring.
Remove the parking brake lever and washer.
Remove the shoe assemblies.
Remove the adjuster screw and spring from the shoe assembly.
To Install:
Use brake cleaning fluid to remove dirt from the brake drum. Check the drums for scoring, cracks and for out-of-round; service the drums as necessary.
Check the wheel cylinders by carefully pulling the lower edges of the wheel cylinder boots away from the cylinders. If there is excessive leakage, the inside of the cylinder will drip fluid; repair or replace as necessary.
Check the flange plate, which is located around the axle, for leakage of differential lubricant.
Lightly lubricate the parking brake cable, parking brake lever where it enters the shoe and the backing plate-to-shoe contact points. Use high temperature, waterproof, grease or special brake lube.
Install the parking brake lever into the secondary shoe with the attaching bolt, spring washer, lockwasher, and nut. It is important that the lever move freely before the shoe is attached. Move the assembly and check for proper action.
Lubricate the adjusting screw and make sure it works freely.
Connect the adjuster screw and spring to the bottom portion of both shoes. Ensure the spring does not interfere with the adjuster rotation when installed. The primary (smaller shoe pad area) to the front and secondary shoe (larger shoe pad area) to the rear of the vehicle.
Install the shoe assembly. Ensuring the shoe webs are positioned correctly against the wheel cylinder.
Install the parking brake cable.
Secure the primary shoes with the hold-down pin and spring.
Install the parking brake strut and the strut spring.
Install the actuator lever and pivot, securing the assembly with the hold-down pin and spring. Install the actuator link and spring.
Install the return springs.
Check the operation of the self-adjusting mechanism by moving the actuating lever by hand.
Raise the lever arm of the actuator until the upper end is clear of the slot in the adjuster screw.
Slide the actuator off the adjuster pin. Disconnect the actuator spring from the shoe.
Remove the hold-down spring assemblies and pins.
Pull the bottom ends of the shoes apart and lift the lower return spring over the anchor plate. Allow the shoe ends to come together and remove the spring.
Remove the shoe assembly, along with the upper return spring and the adjusting screw assembly.
Remove the upper return spring and the adjusting screw assembly from the shoes.
Remove the retaining ring, pin, spring washer, and parking brake lever.
Clean adjuster wheel and the backing plates with a suitable cleaner. Lubricate the backing plate contact points, levers and adjuster with a suitable lubricant.
Assemble the parking lever, spring washer (concave side facing the brake lever), pin, and retaining ring onto the rearward shoe.
Install the adjuster pin in the forward shoe with the pin projecting 0.276 in. (7mm) from the side of the shoe web where the adjuster actuator is installed.
With the brake shoes resting on a flat surface (the shoe with the parking lever to the rear of the vehicle), install the upper return spring.
Install the adjuster screw assembly with the spring clip facing the backing plate.
Place the shoes in position on the backing plate. Do not place the lower shoe webs under the anchor plate.
Install the lower return spring, spread the bottom of the shoes and position the shoe against the backing plate.
Install the hold-down pins and spring assemblies.
Install the adjuster actuator over the end of the adjuster pin so the top leg engages the notch in the adjuster screw.
Install the actuator spring, being careful not to over-stretch it more than 3.27 in. (83mm).
Install the parking brake cable to the lever.
Adjust the parking brake if the shoes will not totally retract.
Install the drum, tire and wheel assembly. Adjust the rear brakes and lower the vehicle.
Item
Part Number
Description
1
2069
Brake Shoe Hold-Down Spring Pin
2
—
Rear Wheel Cylinder Retaining Bolt (2 Req'd)
3
—
Washer (2 Req'd)
4
—
Anchor Pin (Part of 2211)
5
—
Wheel Cylinder
6
2028
Brake Shoe Anchor Pin Guide Plate
7
2A637
Parking Brake Lever
8
2296
Brake Shoe Retracting Spring (Short)
9
2296
Brake Shoe Retracting Spring (Long)
10
2200
Rear Brake Shoe and Lining (Secondary)
11
—
Washer
12
2106
Parking Brake Lever Pin Retainer
13
—
Brake Shoe Adjusting Lever Cable Guide
14
2A642
Primary Brake Shoe Parking Brake Lever Link
15
2A601
Parking Brake Link Spring
16
2068
Brake Shoe Hold-Down Spring
17
2A176
Brake Shoe Adjusting Lever
18
2048
Brake Shoe Adjusting Screw Socket
19
2047
Brake Shoe Adjusting Screw Nut
20
2041
Brake Adjusting Screw
21
2049
Brake Shoe Adjusting Screw Spring
22
2200
Rear Brake Shoe and Lining (Primary)
23
2A178
Brake Shoe Adjusting Lever Cable
24
2211
Brake Backing Plate
Heavy Duty Rear Brake
Item
Part Number
Description
1
—
Rear Wheel Cylinder Retaining Bolt
2
00538
Lock Nut
3
2212
Rear Brake Backing Plate
4
2262
Rear Wheel Cylinder
5
2A642
Primary Brake Shoe Parking Brake Lever Link
6
2A601
Parking Brake Link Spring
7
2A637
Parking Brake Lever
8
2106
Parking Brake Lever Pin Retainer
9
—
Parking Brake Lever Bolt
10
—
Secondary Shoe Assembly
11
2A179
Brake Shoe Adjusting Lever Cable Guide
12
2068
Brake Shoe Hold-Down Spring
13
—
Adjusting Lever Pin
14
—
Adjusting Lever Return Spring
15
2A176
Brake Shoe Adjusting Lever
16
2047
Brake Shoe Adjusting Screw Nut
17
2049
Brake Shoe Adjusting Screw Spring
18
2041
Brake Adjuster Screw
19
—
Primary Shoe Assembly
20
2068
Brake Shoe Hold-Down Spring
21
2200
Rear Brake Shoe and Lining
22
2035
Brake Shoe Retracting Spring
23
2A178
Brake Shoe Adjusting Lever Cable
24
2092
Brake Adjusting Hole Cover
25
2069
Brake Shoe Hold-Down Spring Pin
The rear drum brakes:
Have internal shoes that expand against the brake drum (1126).
Are a single-anchor type.
Are actuated by one rear wheel cylinder (2262).
Have two pistons in the rear wheel cylinder (2261). One exerts force against the upper end of the primary shoe; the other exerts force against the upper end of the secondary shoe.
Adjust rear brake shoes and linings (2200) automatically.
Need manual brake adjustment if the adjusters are not operating properly or after the rear brake shoes and linings have been replaced.
When the brake pedal is applied, hydraulic fluid pressure forces the pistons in the rear wheel cylinder outward, moving the rear brake shoes and linings against the brake drum.
The rear drum brake system includes the parking brake mechanism. Refer to Section 206-05 .
The warning light is triggered by a loss of hydraulic (brake fluid) pressure in the system. look under the car at the inside of all 4 wheels for discoloration from leaking fluid. Inspect the rubber brake hoses. Inspect the area under the master cylinder on the firewall as well. Lastly, a master cylinder can have a leak (blown seal) internally that would not be detectable externally. A dead giveaway for this is brake fluid that is very dark or black.
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