Brake system of motorcycle Harley Sportster XL1200 (2012-2023)

Front brake master cylinder — removal, installation, disassembly, inspection and assembly
General The front brake master cylinder designed for dual disc (two caliper) operation has a larger bore than the master cylinder designed for single disc (one caliper) operation. See Figure 2-48. The bore size is cast into the side of the master...

Front brake caliper: XL models — removal, installation, disassembly and assembly
Removal Note. If only replacing brake pads, do not remove front brake cal-iper(s). For brake pad replacement only, see 1.16 BRAKE PADS AND DISCS: XL MODELS. Caution! Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye...

Front brake caliper: XR 1200X — removal, installation, disassembly and assembly
Removal Note. Do not remove front brake calipers if only replacing brake pads See 1.17 BRAKE PADS AND DISCS: XR 1200X. Caution! Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with...

Rear brake master cylinder: XL models — removal, installation, disassembly, inspection and assembly
General The rear brake master cylinder is mounted transverse to the centerline, beneath the rear fork pivot shaft assembly. If the rear brake feels spongy or excessive pedal travel exists or the brake does not work at all, proceed to Inspection....

Rear brake master cylinder: XR 1200X — removal, installation, disassembly, inspection and assembly
General The rear brake master cylinder is mounted to the right side rider footrest/rear brake pedal bracket. If the rear brake feels spongy or excessive pedal travel exists or the brake does not work at all, proceed with Inspection which follows....

Rear brake master cylinder reservoir
Removal: XL models Caution! Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 4 brake fluid can...

Rear brake caliper: XL models — removal, installation, disassembly and assembly
Removal Note. If only replacing brake pads, do not remove rear brake caliper. For brake pad replacement only, see 1.16 BRAKE PADS AND DISCS: XL MODELS. Caution! Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye contact....

Rear brake caliper: XR 1200X — removal, installation, disassembly and assembly
Removal Note. If only replacing brake pads, do not remove rear brake caliper. See 1.17 BRAKE PADS AND DISCS: XR 1200X. Caution! Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with...

Brake lines — removal and installation
Front brake line FASTENERTORQUE VALUE Brake line banjo bolt20-25 ft·lbs27.1-33.9 Nm Brake line clamp screw, fork bracket45-65 in·lbs5.1-7.4 Nm Brake line clamp screw, steering stem, XL Models120-168 in·lbs13.6-19.0 Nm Brake line clamp screw,...

Bleeding brakes
General Warning! Use denatured alcohol to clean brake system components. Do not use mineral-based solvents (such as gasoline or paint thinner), which will deteriorate rubber parts even after assembly. Deterioration of these components can cause...