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. 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.
Notes:
- Do not remove rear caliper from mounting bracket unless caliper mounting pins and boots require service. Removing caliper from mounting bracket increases the risk of contaminants falling into caliper boots and bushings. This could result in damage to the caliper during vehicle operation.
- It is further not required or recommended to remove or loosen the caliper mounting pins.
- It is not necessary or recommended to remove the rear brake caliper from the caliper mounting bracket to perform caliper service.
- If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.
1. Position vehicle upright on a suitable lift.
2. Place a suitable container under the rear caliper brake line banjo fitting to catch any brake fluid that may leak out. Do not reuse brake fluid.
Note. Dispose of brake fluid in accordance with local regulations.
3. See Figure 2-100. Remove the banjo bolt (1) and both washers (2) to detach rear brake line (3) from brake caliper (4). Discard washers.
![](https://motoinstruction.ru/img/harley/12/117717.jpg)
Figure 2-100. Rear caliper assembly: 1. Banjo bolt; 2. Washer (2); 3. Rear brake line; 4. Brake caliper; 5. Caliper mounting bracket; 6. Bleeder valve; 7. Damper
4. Remove pad pin plug.
5. See Figure 2-101. Remove brake pad pin.
![](https://motoinstruction.ru/img/harley/12/117718.jpg)
Figure 2-101. Brake pad pin (plug removed)
6. See Figure 2-102. Remove brake pads (15).
![](https://motoinstruction.ru/img/harley/12/117719.jpg)
Figure 2-102. Rear brake caliper assembly: XL Models: 1. Caliper mounting bracket; 2. Pad spring; 3. Caliper pin boot; 4. Damper; 5. Mounting bracket bolt pin (do not remove); 6. Caliper body; 7. Caliper bolt pin (do not remove); 8. Caliper bushing boot; 9. Pad pin plug; 10. Pad pin; 11. Bleeder nipple cap; 12. Bleeder valve; 13. Brake pad (2); 14. Pad retainer (2); 15. Brake pad set (includes item 20); 16. Piston; 17. Piston seal; 18. Dust seal; 19. Piston kit; 20. Retainer clip (not sold separately)
7. Remove rear wheel. See 2.5 WHEELS, Rear Wheel.
8. Remove rear brake caliper and caliper mounting bracket.
Disassembly
1. See Figure 2-102. Remove pad spring (2). Do not remove bleeder valve (12) at this time.
2. See Figure 2-103. Install a discarded brake pad in the caliper with the backing plate (4) facing the piston. Position the brake pad so the friction material (3) is against the back of the caliper, as shown.
![](https://motoinstruction.ru/img/harley/12/117720.jpg)
Figure 2-103. Preparing caliper for piston removal: 1. Brake caliper; 2. Brake pad pin; 3. Brake pad friction material; 4. Brake pad backing plate; 5. Brake caliper mounting bracket
3. 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.
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.
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.
4. See Figure 2-104. Gently apply low pressure compressed air to banjo bolt hole (3) to force piston from caliper bore.
![](https://motoinstruction.ru/img/harley/12/117721.jpg)
Figure 2-104. Removing piston (caliper removed from mounting bracket): 1. Low pressure air nozzle; 2. Brake caliper; 3. Banjo bolt hole; 4. Brake pad
5. Remove brake pad pin and brake pad from caliper.
6. See Figure 2-102. Remove piston (16) from caliper bore by hand. If necessary, gently wiggle piston to completely remove.
Note. A damaged piston bore will leak when reassembled. Do not use metal objects to remove or install components in piston bore. Prevent damage to piston, seal and bore by only using a wooden toothpick when servicing caliper.
7. See Figure 2-105. Using a wooden toothpick (1), remove dust seal (2) and piston seal (3) from caliper bore. Discard seals.
![](https://motoinstruction.ru/img/harley/12/117722.jpg)
Figure 2-105. Caliper seals: 1. Wooden toothpick; 2. Dust seal; 3. Piston seal
8. See Figure 2-102. If necessary, remove bleeder valve (12).
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. Clean piston bore with denatured alcohol.
2. Clean all rubber parts with DOT 4 BRAKE FLUID. Do not contaminate with mineral oil or other solvents. 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 as necessary.
- a. Check piston for pitting, scratching or corrosion on outside surfaces.
- b. Inspect caliper piston bore. Do not hone bore. If bore shows pitting or corrosion, replace caliper.
- c. Inspect pad pin 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. 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.
Lubricating rear caliper bolt pins and boots
1. Apply approximately 0.4 g of G40M BRAKE GREASE inside caliper bushing boot and caliper pin boot.
2. See Figure 2-106. 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/12/117723.jpg)
Figure 2-106. Assembling rear brake caliper to mounting bracket: 1. Rear brake caliper; 2. Caliper mounting bracket; 3. Caliper bushing boot; 4. Caliper pin boot; 5. Bolt pin (caliper); 6. Bolt pin (mounting bracket); 7. Tapered shoulder; 8. Boot lip
3. Insert mounting bracket bolt pin (6) into caliper bushing boot (3).
Assembly
Note. Use ONLY KS62F assembly grease for lubrication. Use of DOT 4 brake fluid will result in increased brake pedal 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 piston. See Figure 2-107.
- b. All surfaces of piston seal and dust seal.
![](https://motoinstruction.ru/img/harley/12/117724.jpg)
Figure 2-107. Piston nose radius
Note. A damaged piston bore will leak when reassembled. Do not use metal objects to remove or install components in piston bore. Prevent damage to bore by only using a wooden toothpick when servicing caliper.
2. See Figure 2-105. Install a new piston seal (3) and a new dust seal (2) into piston bore.
3. Carefully insert piston by hand, nose radius first (see Figure 2-102), into caliper bore. If installation shows resistance, remove piston and check that seals are properly installed and fully seated in grooves.
4. See Figure 2-102. Install bleeder valve (12) on caliper housing if removed. Do not tighten bleeder valve at this time.
5. See Figure 2-108. Install pad spring in channel. Press firmly into place.
![](https://motoinstruction.ru/img/harley/12/117725.jpg)
Figure 2-108. Rear caliper pad spring
Installation
FASTENER | TORQUE VALUE | |
Caliper to mouting bracket: XL Models | 87-130 in·lbs | 9.8-14.7 Nm |
Caliper bolt pin: XL Models | 15-18 ft·lbs | 19.6-24.5 Nm |
Brake line banjo bolt | 20-25 ft·lbs | 27.1-33.9 Nm |
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 |
1. See Figure 2-109. Before installing caliper, make sure that retainer clip is properly installed on mounting bracket.
![](https://motoinstruction.ru/img/harley/12/117726.jpg)
Figure 2-109. Retainer clip
2. See Figure 2-102. Install rear caliper onto the mounting bracket:
- a. Apply a small amount of LOCTITE 272 HIGH STRENGTH/HIGH TEMPERATURE THREADLOCKER AND SEALANT (red/orange) to mounting bracket bolt pin (5) threads.
- b. Place the rear caliper assembly (6) onto the mounting bracket (1). Using an open end wrench, thread mounting bracket bolt pin into caliper mounting bracket. Tighten to 87-130 in·lbs (9.8-14.7 Nm).
- c. Apply a small amount of LOCTITE 272 HIGH STRENGTH/HIGH TEMPERATURE THREADLOCKER AND SEALANT (red/orange) to threads of caliper bolt pin (7).
- d. Slide caliper bolt pin through front mounting hole in caliper (6). Carefully insert bolt pin shaft into caliper pin boot (3) in mounting bracket (1).
- e. Screw bolt pin into caliper. Tighten to 15-18 ft·lbs (19.6-24.5 Nm).
3. Install rear brake caliper and mounting bracket assembly onto vehicle.
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.
4. See Figure 2-110. 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 20-25 ft·lbs (27.1-33.9 Nm).
![](https://motoinstruction.ru/img/harley/12/117727.jpg)
Figure 2-110. Rear caliper assembly: 1. Banjo bolt; 2. Sealing washer (2); 3. Rear brake line; 4. Brake caliper; 5. Caliper mounting bracket; 6. Damper
Note. Front brake pad sets cannot be used on rear brake calipers.
5. Insert brake pads into caliper with friction material on pad facing brake disc. Curved portion of pad fits into recessed area of caliper. Make sure brake pad front mounting tab (fits into slot in caliper mounting bracket.
6. See Figure 2-102. Press brake pads (15) tightly up against pad spring (2) and install pad pin (10). Tighten to 131-173 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.
- See Figure 2-108. Pad spring orientation must match.
- Pad front mounting tabs must be fully seated in mounting bracket slot.
- Pads must be pushed tight up against pad spring before pad pin is installed.
7. See Figure 2-102. Install pad pin plug (9). Tighten to 18-25 in·lbs (2.0-2.9 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.
Notes:
- If DOT 4 BRAKE FLUID contacts painted surfaces, IMMEDIATELY flush area with clear water.
- Rear brake master cylinder reservoir must be in a level position when filling and checking fluid level.
- See Figure 2-111. Reservoir cover (2) may be removed from rear brake master cylinder reservoir (1) to more easily verify fluid level in reservoir.
![](https://motoinstruction.ru/img/harley/12/117728.jpg)
Figure 2-111. Rear brake master cylinder reservoir: 1. Rear brake master cylinder reservoir; 2. Reservoir cover; 3. Upper fluid level; 4. Lower fluid level; 5. Reservoir cap
8. See Figure 2-111. To remove reservoir cover, grasp cover (2) and gently pull straight out from reservoir (1).
9. Remove rear brake master cylinder reservoir cap (5). Add DOT 4 BRAKE FLUID to reservoir until fluid reaches upper fluid level (3). Do not overfill reservoir. Do not reuse brake fluid.
Warning! After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury.
10. Bleed brake system. See 2.17 BLEEDING BRAKES.
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.
11. Verify proper operation of master cylinder relief port.
- a. Press against rear brake caliper to push caliper piston back into its bore. This pushes brake fluid back through master cylinder and verifies that relief port is not plugged.
- b. Pump brake pedal until caliper piston pushes pads against disc and pressure is returned to brake system.
12. Add DOT 4 BRAKE FLUID to reservoir until fluid reaches upper fluid level.
13. Install reservoir cover if removed.
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.
14. Test brake system.
- a. Turn ignition switch ON. Pump brake pedal to verify operation of stop lamp.
- b. Test ride motorcycle at low speed. If brakes feel spongy, bleed 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.