Removal
Note. If only replacing brake pads, do not remove rear brake caliper. Should pad replacement be necessary, see 1.10 Brake pads and discs.
1. Remove saddlebag if necessary to gain access to rear brake caliper.
Caution! Damaged banjo bolt surfaces will leak when reassembled. Prevent damage to seating surfaces by carefully removing brake line components.
2. Remove banjo bolt and both steel/rubber washers to detach rear brake line from caliper. Discard washers.
3. With motorcycle supported from underneath, remove axle nut and rear axle adjuster. Pull axle from the left side through right side rear fork arm and caliper only. Do not pull axle all the way out. See 2.23 Rear wheel.
4. Lift rear caliper away from axle and rear fork.
Disassembly
PART NO. | SPECIALTY TOOL |
HD-43293 | Brake caliper piston remover |
1. See Figure 2-55. Remove pad pins (10), brake pads (7) and bridge bolts (11) to separate caliper housings (1,8).
![](https://motoinstruction.ru/img/harley/2/111340.jpg)
Figure 2-55. Rear brake caliper: 1. Inside caliper housing; 2. Square seal; 3. Wiper; 4. Piston; 5. Crossover O-ring; 6. Anti-rattle spring; 7. Brake pads; 8. Outside caliper housing; 9. Decal; 10. Pad pin; 11. Bridge bolt; 12. Bleeder valve; 13. Rubber bumper
2. Remove anti-rattle spring (6). If necessary, remove bleeder valve (12).
3. If necessary, cut rubber bumper (13) to remove.
Warning! Low pressure compressed air can blow debris into your face and eyes. Always wear eye protection or a face shield when using pressurized air. Failure to take adequate safety precautions could result in death or serious injury.
4. See Figure 2-56. Remove and discard both crossover o-rings (1) from inside caliper housing.
![](https://motoinstruction.ru/img/harley/2/111341.jpg)
Figure 2-56. Crossover о-rings and pistons: 1. Crossover o-rings; 2. Pistons
5. See Figure 2-57. Remove pistons.
- a. Place BRAKE CALIPER PISTON REMOVER (HD-43293) between caliper housings.
- b. Insert three bridge bolts and tighten securely.
- c. If the bleeder valve was removed, loosely reinstall or place a gloved finger over the bleeder valve hole on outside caliper housing.
- d. Apply low pressure compressed air to banjo bolt hole to remove pistons from caliper bores.
- e. Remove bridge bolts and remove tool.
![](https://motoinstruction.ru/img/harley/2/111342.jpg)
Figure 2-57. Removing pistons: 1. Low pressure air hose; 2. Bridge bolt; 3. Brake caliper piston remover (Part No. HD-43293)
6. If necessary, wiggle pistons from caliper bores to completely remove. Discard all removed parts.
Caution! Damaged pistons or piston bores will leak when reassembled. Do not use metal objects to remove or install objects from piston bores. Prevent damage to bores by only using a wooden toothpick when servicing calipers.
7. See Figure 2-58. Using a wooden toothpick (1), remove wiper (2) and square seal (3) from each caliper bore.
![](https://motoinstruction.ru/img/harley/2/111343.jpg)
Figure 2-58. Wipers and square seals: 1. Wooden toothpick; 2. Wiper; 3. Square seal
Cleaning, inspection and repair
Warning! Clean brake system components using denatured alcohol. Do not use mineral-base cleaning solvents, such as gasoline or paint thinner. Use of mineral-base solvents causes deterioration of rubber parts that continues after assembly. This may result in improper brake operation which could result in death or serious injury.
1. Clean all parts with denatured alcohol or DOT 5 SILICONE BRAKE FLUID. Do not contaminate with mineral oil or other solvents. Wipe parts dry with a clean, lint free cloth. Blow out drilled passages and bore with a clean air supply. Do not use wire or similar instrument to clean drilled passages.
2. Carefully inspect all components. Replace any parts that appear damaged or worn.
- a. Check pistons for pitting, scratches or corrosion on face and also on ground surfaces.
- b. Inspect caliper piston bore. Do not hone bore. If bore should show pitting or corrosion, replace caliper.
- c. Inspect rubber damper for cuts, tears, or signs of deterioration.
- d. Always replace wipers, square seals and crossover о-rings after disassembly.
- e. Inspect brake pads and brake disc. See 1.10 Brake pads and discs.
- f. Inspect pad pins for wear and grooving, if wear is more than 0.38 mm (0.015 in.), replace both pins.
- g. If decal on outside housing is removed, scrape remaining adhesive from surface with a razor blade.
Assembly
Caution! Do not use DOT 5 SILICONE BRAKE FLUID for lubrication. Use of DOT 5 SILICONE BRAKE FLUID will result in increased lever travel.
1. Lubricate the following parts prior to assembly using a light coat of G.E. VERSILUBE® #G322 L SILICONE GREASE (marked "Piston Lube") from the SERVICE PARTS KIT. All other surfaces must be dry for assembly.
- a. Lubricate nose radius and outside diameter of piston. Apply lube to inside of caliper piston bores.
- b. Apply lube to inside diameter of new seals and wipers.
Caution! Damaged piston bores will leak when reassembled. Do not use metal objects to remove or install objects from piston bores. Prevent damage to bores by only using a wooden toothpick when servicing calipers.
2. See Figure 2-55. Install a new square seal (2) and a new wiper (3) into each piston bore.
3. Carefully insert pistons (4) by hand into bores of inside and outside caliper housings (1, 8). If resistance is felt, remove piston and check that seal and wiper are properly installed.
4. Assemble caliper housings.
- a. If removed, install bleeder valve (12) on outside caliper housing (8). Tighten bleeder valve to 9-11 Nm (80-100 in-lbs).
- b. Place outside caliper housing (8) on workbench with decal side down. Install anti-rattle clip (6) in channel with indent facing upwards.
- c. Place two new crossover o-rings (5) into grooves on inside caliper housing (1).
- d. Mate inside and outside caliper housings (1, 8) using three bridge bolts (11). Loosely install bridge bolts.
- e. Check that anti-rattle clip is still seated between caliper housings.
- f. Tighten bridge bolts to 38-52 Nm (28-38 ft-lbs).
- g. If rubber bumper (13) on outside housing was removed, lubricate new part before installation.
Warning! Always replace brake pads in complete sets for correct brake operation. Never replace just one brake pad. Failure to install brake pads as a set could result in death or serious injury.
5. See Figure 2-59. Insert new set of brake pads into caliper with friction material on pad facing opening for brake disc. Curved portion of pad must face upward when caliper is installed.
![](https://motoinstruction.ru/img/harley/2/111344.jpg)
Figure 2-59. Brake pads: 1. Two tabs on backing plate; 2. Single square tab on backing plate; 3. Curved portion
Note. Install pad with the two tabs on the backing plate on the inboard side of the rear caliper.
6. See Figure 2-55. If necessary, Install new pad pins (10). Pad pins will give an audible click when inserted into inside housing. Tighten to 20-23 Nm (180-200 in-lbs).
Note. If pad pins do not fit, check the following:
- You are using a set of pads, not two identical pads.
- Anti-rattle clip orientation matches Figure 2-60.
- Pads must be pushed tight against the anti-rattle clip before the pad pins can be installed.
![](https://motoinstruction.ru/img/harley/2/111345.jpg)
Figure 2-60. Anti-rattle clip: 1. Bleeder valve; 2. Anti-rattle clip; 3. Indent; 4. Rubber bumper
Installation
1. Place caliper on rear axle with notch inside rear fork weldment. Verify that rubber bumper is contacting underside of the caliper weldment for the full length of bumper. Install rear axle and check drive belt tension. See 2.23 Rear wheel.
Caution! To avoid leakage, verify that the washers, banjo bolt, brake line and caliper bore are completely clean.
2. Lubricate new steel/rubber washers with DOT 5 SILICONE BRAKE FLUID. Connect brake line to caliper using two new washers and banjo bolt. Tighten to 23-31 Nm (17-23 ft-lbs).
Warning! Direct contact of DOT 5 brake fluid with eyes may cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 5 brake fluid may cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN.
3. Remove radiator side cover to access master cylinder. See 2.19 Rear brake master cylinder/reservoir. Remove cover from rear brake master cylinder. Fill master cylinder with DOT 5 SILICONE BRAKE FLUID. Verify that fluid level is at the FILL LEVEL boss when the motorcycle is level.
Warning! Whenever brake calipers are installed, BEFORE moving motorcycle, you must pump brake fluid until the pistons push the pads against the brake disc. If you don’t pump fluid pressure up again, the brakes will not be available to stop the motorcycle which could result in death or serious injury.
4. Bleed brake system. See 1.9 Bleeding brakes.
Warning! A plugged or covered relief port can cause brake drag or lockup, which may result in loss of vehicle control which could result in death or serious injury.
5. Verify proper operation of master cylinder relief port. Actuate brake pedal with cover removed. A slight spurt of fluid will break surface if all internal components are working properly.
6. Install gasket and cover on master cylinder. Tighten cover screws to 0.7-0.9 Nm (6-8 in-lbs).
7. Install radiator side cover.
8. Install right saddlebag if necessary.
Warning! After completing repairs or bleeding the system, always test motorcycle brakes at low speed. If brakes are not operating properly or braking efficiency is poor, testing at high speeds could result in death or serious injury.
9. Test brake system.
- a. Turn ignition switch ON. Pump brake foot pedal to verify operation of brake lamp.
- b. Test ride motorcycle. If brakes feel spongy, bleed the system again. See 1.9 Bleeding brakes.
Note. Avoid making hard stops for the first 100 miles (160 km). This allows the new pads to become conditioned to the brake discs.