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 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 cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN.
Note. Damaged banjo bolt surfaces will leak when reassembled. Prevent damage to seating surfaces by carefully removing brake line components.
Notice: DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage.
Note. If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.
1. See Figure 2-61. Remove bleeder nipple cap (9) from bleeder valve (8) on front brake caliper (4).
![](https://motoinstruction.ru/img/harley/12/117678.jpg)
Figure 2-61. Front caliper assembly: 1. Banjo bolt; 2. Washer (2); 3. Front brake line; 4. Brake caliper; 5. Caliper mounting bracket; 6. Mounting bolt (2) (12 pt/10 mm); 7. Pad pin plug; 8. Bleeder valve; 9. Bleeder nipple cap
2. See Figure 2-62. Install end of a length of 5/16 in (7.9 mm) ID clear plastic tubing over caliper bleeder valve, while placing free end in a suitable container. Open bleeder valve about 1/2 turn. Pump brake hand lever repeatedly to drain brake fluid. Close bleeder valve.
![](https://motoinstruction.ru/img/harley/12/117679.jpg)
Figure 2-62. Bleeding hydraulic system
Note. Dispose of brake fluid in accordance with local regulations.
3. See Figure 2-61. Remove the banjo bolt (1) and both washers (2) to detach front brake line (3) from caliper (4). Discard washers.
4. Remove pad pin plug (7).
5. See Figure 2-63. Loosen, but do not remove, brake pad pin.
![](https://motoinstruction.ru/img/harley/12/117680.jpg)
Figure 2-63. Brake pad pin (plug removed)
6. See Figure 2-61. Remove both mounting bolts (6) (12 pt/10 mm). Pull caliper and mounting bracket assembly rearward to disengage from brake disc.
Disassembly
1. See Figure 2-64. Remove brake pad pin (14) and brake pads (8) from caliper body (15).
![](https://motoinstruction.ru/img/harley/12/117681.jpg)
Figure 2-64. Front brake caliper assembly: 1. Caliper bracket; 2. Caliper pin boot; 3. Screw (2); 4. Bolt pin (caliper); 5. Pad retainer (2); 6. Insulator (2); 7. Brake pad (2); 8. Brake pad set (includes item 9); 9. Retainer clip (not sold separately); 10. Bleeder valve; 11. Bleeder nipple cap; 12. Caliper bushing boot; 13. Pad pin plug; 14. Pad pin; 15. Caliper body; 16. Pad spring; 17. Piston (2); 18. Piston seal (2); 19. Dust seal (2); 20. Piston kit; 21. Bolt pin (mounting bracket)
2. Slide brake caliper off mounting bracket (1).
3. Remove pad spring (16). Do not remove bleeder valve (10) at this time.
4. See Figure 2-65. Install a discarded brake pad in the caliper (1) with the backing plate (4) facing the pistons. Position the brake pad so the friction material (3) is against the back of the caliper, as shown.
![](https://motoinstruction.ru/img/harley/12/117682.jpg)
Figure 2-65. Preparing caliper for piston removal: 1. Brake caliper; 2. Brake pad pin; 3. Brake pad friction material; 4. Brake pad backing plate
5. Loosely install brake pad pin (2) to hold brake pad in place.
Warning! Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates.
Note. Do not damage banjo bolt sealing surface or threads of banjo bolt hole in brake caliper. Use an air nozzle with a rubber tip.
Caution! When removing piston with compressed air, piston can develop considerable force and fly out of caliper bore. Keep hands away from piston to avoid possible injury.
6. See Figure 2-66. Gently apply low pressure compressed air to banjo bolt hole (3) to force pistons from caliper bores.
![](https://motoinstruction.ru/img/harley/12/117683.jpg)
Figure 2-66. Removing pistons: 1. Low pressure air nozzle; 2. Brake caliper; 3. Banjo bolt hole; 4. Brake pad
7. Remove brake pad pin and brake pad.
8. See Figure 2-64. Remove both pistons (17) from caliper bores by hand. If necessary, wiggle pistons gently to completely remove.
Note. Damaged piston bores will leak when reassembled. Do not use metal objects to remove or install objects from piston bores. Prevent damage to pistons, seals and bores by only using a wooden toothpick when servicing calipers.
9. See Figure 2-67. Using a wooden toothpick (1), remove dust seal (2) and piston seal (3) from each caliper bore. Discard seals.
![](https://motoinstruction.ru/img/harley/12/117684.jpg)
Figure 2-67. Caliper seals: 1. Wooden toothpick; 2. Dust seal; 3. Piston seal
10. See Figure 2-64. If necessary, remove bleeder valve (10).
Cleaning, inspection and repair
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 brake failure, which could result in death or serious injury.
1. See Figure 2-64. Wipe old lubrication from inside of caliper pin boot (2) and caliper bushing boot (12) with a soft, clean cloth.
2. Clean all other rubber parts with DOT 4 BRAKE FLUID. Do not contaminate with mineral oil or other solvents. Clean all metal parts with denatured alcohol. Wipe parts dry with a clean, lint-free cloth.
Warning! Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates.
3. Blow out drilled passages and piston bore with low pressure compressed air from a clean air supply. Do not use a wire or similar instrument to clean drilled passages.
4. Carefully inspect all components. Replace any parts that appear damaged or worn.
- a. Check pistons (17) for pitting, scratching or corrosion on outside surfaces.
- b. Inspect caliper piston bores. Do not hone bores. If bores show pitting or corrosion, replace caliper.
- c. Inspect pad pin (14) for grooving and wear. Measure the pad pin diameter in an unworn area, and then in the area of any grooving or wear. If wear is more than 0.011 in (0.28 mm), replace pad pin.
- d. Inspect caliper bolt pin (4). If damaged or excessively worn, replace brake caliper assembly.
- e. Inspect caliper bushing boot and caliper pin boot. If worn or damaged, replace.
- f. Always replace all seals after disassembly.
Warning! Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury.
5. Inspect brake pads and brake disc. Replace if necessary.
- a. See 1.16 BRAKE PADS AND DISCS: XL MODELS for specifications.
- b. See 2.5 WHEELS for brake disc replacement procedure.
Assembly
FASTENER | TORQUE VALUE | |
Brake caliper bleeder valve | 35-61 in·lbs | 4.0-6.9 Nm |
Note. Use ONLY KS62F assembly grease for lubrication. Use of DOT 4 BRAKE FLUID will result in increased brake lever travel.
1. Lubricate the following parts prior to assembly using a light coat of KS62F assembly grease from the service parts kit. All other surfaces must be dry for assembly.
- a. Nose radius of pistons. See Figure 2-68.
- b. All surfaces of piston seals and dust seals.
Note. Damaged piston bores will leak when reassembled. Do not use metal objects to remove or install objects in piston bores. Prevent damage to bores by only using a wooden toothpick when servicing calipers.
2. See Figure 2-67. Install a new piston seal (3) and a new dust seal (2) into each piston bore.
3. See Figure 2-68. Carefully insert pistons by hand, nose radius first, into caliper bores. If installation shows resistance, remove piston(s) and check that seals are properly installed and fully seated in grooves.
![](https://motoinstruction.ru/img/harley/12/117685.jpg)
Figure 2-68. Piston nose radius
4. See Figure 2-64. Install bleeder valve (10) on caliper housing if removed. Tighten bleeder valve to 35-61 in·lbs (4.0-6.9 Nm).
5. See Figure 2-69. Install pad spring in channel. Press firmly into place.
![](https://motoinstruction.ru/img/harley/12/117686.jpg)
Figure 2-69. Front caliper pad spring
Lubricating front caliper bolt pins and boots
1. See Figure 2-70. Apply approximately 0.4 g of G40M BRAKE GREASE inside caliper bushing boot (3) and caliper pin boot (4).
![](https://motoinstruction.ru/img/harley/12/117687.jpg)
Figure 2-70. Lubricating caliper boots and pins: 1. Front brake caliper; 2. Caliper mounting bracket; 3. Caliper bushing boot; 4. Caliper pin boot; 5. Caliper bolt pin; 6. Bracket bolt pin
2. See Figure 2-71. Apply G40M BRAKE GREASE inside boot lip (8) to prevent sticking between boots (3, 4) and bolt pins (5, 6).
![](https://motoinstruction.ru/img/harley/12/117688.jpg)
Figure2-71.Assembling front brake caliperand mounting bracket: 1. Front brake caliper; 2. Caliper mounting bracket; 3. Caliper bushing boot; 4. Caliper pin boot; 5. Caliper bolt pin; 6. Bracket bolt pin; 7. Tapered shoulder; 8. Boot lip
3. Assemble brake caliper and mounting bracket, carefully sliding bolt pins into boots. Slide brake caliper all the way onto mounting bracket until boot lips fit over tapered shoulders (7) of bolt pins.
Installing brake pads in caliper
FASTENER | TORQUEVALUE | |
Brake pad pin | 131-173 in·lbs | 14.8-19.6 Nm |
Brake pad pin plug | 18-25 in·lbs | 2.0-2.9 Nm |
Note. Rear brake pads cannot be used on front brake calipers.
1. See Figure 2-72. Insert one set of brake pads (1) into caliper with friction material on pad facing opening for brake disc. Curved portion of pad fits into recessed area of caliper. Make sure brake pad front mounting tab (2) fits into slot (5) in caliper mounting bracket (4).
![](https://motoinstruction.ru/img/harley/12/117689.jpg)
Figure 2-72. Front brake pads: 1. Brake pad; 2. Front mounting tab; 3. Pad pin hole; 4. Front caliper mounting bracket; 5. Slot
2. See Figure 2-64. Press brake pads (8) tightly up against pad spring (16) and install pad pin (14). Tighten to 131173 in·lbs (14.8-19.6 Nm).
Note. If pad pin does not fit, check the following:
- You are using a set of pads, not two identical pads.
- Pad spring orientation must match Figure 2-69.
- See Figure 2-72. Pad front mounting tabs (2) must be fully seated in mounting bracket slot (5).
- Pads must be pushed tight up against pad spring before pad pin is installed.
3. See Figure 2-64. Install pad pin plug (13). Tighten to 18-25 in·lbs (2.0-2.9 Nm).
Installation
FASTENER | TORQUE VALUE | |
Axle, front, nut | 60-65 ft·lbs | 81-88 Nm |
Axle, front, pinch screw: XL Models | 21-27 ft·lbs | 28.5-36.6 Nm |
Brake caliper, front, mounting bolt | 28-38 ft·lbs | 38.0-51.6 Nm |
Brake line banjo bolt | 20-25 ft·lbs | 27.1-33.9 Nm |
Brake master cylinder, front, reservoir cover screw | 9-17 in·lbs | 1.0-2.0 Nm |
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 cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN.
Notice: DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage.
Note. If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.
1. Dual Caliper Models: Align calipers to brake discs.
- a. Tighten axle nut to 60-65 ft·lbs (81-88 Nm).
- b. Loosen axle pinch screw nut.
- c. Position right fork leg against bearing spacer. Tighten axle pinch screw to 21-27 ft·lbs (28.5-36.6 Nm).
2. See Figure 2-73. Place brake caliper (4) with mounting bracket (5) over brake disc with bleeder valve (8) facing upwards. Install mounting bolts (6) into mounting holes on fork leg. Tighten to 28-38 ft·lbs (38.0-51.6 Nm).
![](https://motoinstruction.ru/img/harley/12/117690.jpg)
Figure 2-73. Front caliper assembly: 1. Banjo bolt; 2. Washer (2); 3. Front brake line; 4. Brake caliper; 5. Caliper mounting bracket; 6. Mounting bolt (2) (12 pt/10 mm); 7. Pad pin plug; 8. Bleeder valve; 9. Bleeder nipple cap
Notice: Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and caliper bore are clean and undamaged before assembly.
Note. Brake caliper housing has a positive stop for banjo fitting. When tightening banjo bolt into brake caliper in the next step, rotate banjo fitting clockwise until it contacts positive stop.
3. Position a new washer (2) on each side of hydraulic brake line (3) banjo fitting. Insert banjo bolt (1) through washers and fitting. Thread bolt into caliper housing. Tighten to 2025 ft·lbs (27.1-33.9 Nm).
4. Dual Caliper Models: Repeat previous two steps for other brake caliper.
5. Remove cover screws, top cover and gasket from front brake master cylinder reservoir.
Notes:
- See Figure 2-74. Do not use sight glass to determine maximum fluid level. Sight glass should only be used as a visual indicator that fluid level is low and needs attention.
- Cover handlebar switches with a shop towel before adding brake fluid to front master cylinder reservoir. Spilling brake fluid on handlebar switches may render them inoperative.
- Use only DOT 4 BRAKE FLUID from a sealed container.
- Do not overfill reservoir. Do not reuse old brake fluid.
![](https://motoinstruction.ru/img/harley/12/117691.jpg)
Figure 2-74. Filling front master cylinder reservoir: 1. Cast-in ridge; 2. Sight glass
6. See Figure 2-74. Add enough DOT 4 BRAKE FLUID to reservoir to bring fluid level even with ridge cast into inside of reservoir, about 1/4 in (6.35 mm) below top edge.
Warning! After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury.
7. Bleed brake system. See 2.17 BLEEDING BRAKES.
Note. On dual caliper models, bleed both calipers.
Warning! A plugged or covered relief port can cause brake drag or lock-up, which could lead to loss of control, resulting in death or serious injury.
8. Verify proper operation of master cylinder relief port. Turn handlebar to level reservoir. Squeeze brake lever slowly with reservoir cover removed. A slight spurt of fluid will break the surface if all internal components are working properly.
9. See Figure 2-74. Add enough DOT 4 BRAKE FLUID to reservoir to bring fluid level even with ridge cast into inside of reservoir, about 1/4 in (6.35 mm) below top edge.
10. Install gasket and cover on master cylinder with screws. Tighten to 9-17 in·lbs (1.0-2.0 Nm).
Warning! After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury.
11. Test brake system.
- a. Turn ignition switch ON. Squeeze brake hand lever to verify operation of the stop lamp.
- b. Test ride the motorcycle. If the brakes feel spongy, bleed the system again. See 2.17 BLEEDING BRAKES.
Note. Avoid making hard stops for the first 100 mi (160 km). This allows the new pads to become conditioned to the brake discs.