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The front disc brake on my 150 LX works great. However, the plunger on the brake reservior does not seem to be coming back out fully. Thus there is about 1/4" play in the brake lever allowing the brake light switch to stay extended keeping the brake light on all the time.
Any suggestions on a fix?
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The Hornet (GT200, aka Love Bug) and 'Dimples' - a GTS 300
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You may find you can screw the switch in a little more - sometimes they are screwed out a few turns to help get the brake light on when just gently applying the brakes.
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lostboater wrote:
the plunger on the brake reservior does not seem to be coming back out fully.
That doesn't sound right.

What's the history? Year/miles on scoot? Recent fluid/pad change?
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jimc wrote:
You may find you can screw the switch in a little more - sometimes they are screwed out a few turns to help get the brake light on when just gently applying the brakes.
Yep, tried that. Screwed so good it broke. But the 1/4" of play in the lever is more than screwing in the switch will cover.
It is 2006. The brake has been happy for years and about 13,000 miles. It all relates to the plunger. Checked my other scooters and they all push the lever back on the switch.
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lostboater wrote:
It is 2006. The brake has been happy for years and about 13,000 miles.
Sounds like it's way overdue for a fluid change, recommended interval is 2 years. Just might fix it. If not probably looking at a new master.

At 13k might be time for new pads as well.
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bluecloud wrote:
lostboater wrote:
It is 2006. The brake has been happy for years and about 13,000 miles.
Sounds like it's way overdue for a fluid change, recommended interval is 2 years. Just might fix it. If not probably looking at a new master.

At 13k might be time for new pads as well.
I am curious as to what your basis on old fluid affecting the this problem is.
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UTC quote
lostboater wrote:
bluecloud wrote:
lostboater wrote:
It is 2006. The brake has been happy for years and about 13,000 miles.
Sounds like it's way overdue for a fluid change, recommended interval is 2 years. Just might fix it. If not probably looking at a new master.

At 13k might be time for new pads as well.
I am curious as to what your basis on old fluid affecting the this problem is.
moisture in fluid over time can cause corrosion. that is why changing fluid is recommended every 2 years by manufacture.
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And corrosion in the bore could be restricting piston travel.

Bleed it. Frst step in troubleshooting and minimal $$.
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bluecloud wrote:
And corrosion in the bore could be restricting piston travel.

Bleed it. Frst step in troubleshooting and minimal $$.
Actually the simplist cure is a overhaul of the master cylinder which just involves pulling the plunger and putting a new one in. Can't find one in the Vespa parts manual, which is why I put the question out on the here. Talked to my scooter guy today and he says they are pretty universal and he has one that will fit. Pop a washer and insert a new plunger, spring and rubber and you are done.
⬆️    About 4 months elapsed    ⬇️
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Back working on scooters again at home. This problem was none of the above. Upon further investigaton it was the brake lever itself. It was either defective in that it was to short to hit the switch, or is the wrong lever. Bought a set of levers from OppsClunkThud and it works great.
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