Harley Davidson 2009 Dyna Models. Service manual — page 11

Remove pivot pin (15) and brake hand lever (17).

Carefully remove wiper (2) with pick or similar tool.

Remove piston cap (3).

Remove piston (5) with O-ring (4) and primary cup (6).

10. Remove spring (7).

11. Remove both screws (13), cover (11) and the cover gasket

(10).

sm03168

Groove

5/32 in. (4 mm) thick cardboard insert

Figure 2-64. Cardboard Insert

CLEANING AND INSPECTION

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. (00291a)

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. (00061a)

Clean all parts with denatured alcohol or D.O.T. 4 BRAKE
FLUID. Do not contaminate with mineral oil or other
solvents. Wipe dry with a clean, lint free cloth. Blow out
drilled passages and bore with a clean air supply. Do not
use a wire or similar instrument to clean drilled passages
in bottom of reservoir.

Carefully inspect all parts for wear or damage and replace
as necessary.

Inspect the piston bore in the master cylinder housing for
scoring, pitting or corrosion. Replace the housing if any
of these conditions are found.

Inspect the outlet port that mates with the brake line fitting.
As a critical sealing surface, replace the housing if any
scratches, dents or other damage is noted.

Inspect the cover gasket for cuts, tears or general deteri-
oration. Replace as necessary.

ASSEMBLY AND INSTALLATION

NOTE

Always reassemble the master cylinder using new parts from
the correct repair kit.

See

Figure 2-63

. Fit o-ring (4) into groove on outboard

side of piston (5) (pin side).

Fit primary cup (6) over lip on inboard side of piston, so
that closed side (smaller OD) contacts shoulder.

Coat piston bore of master cylinder reservoir with special
lubricant (1) supplied in the service parts kit. Also apply
the lubricant to OD of installed o-ring (4) and primary cup
(6).

Insert spring (7) into piston bore, so that it seats against
counterbore (recess) at bottom.

Slide piston over spring.

Fit wiper (2) over piston cap (3) so that flat side of wiper
contacts cap shoulder.

Fit piston cap over piston pin (5).

Press down on wiper until it contacts the counterbore.
Larger OD of wiper must be completely seated in groove
on outlet side of piston bore.

Install the master cylinder reservoir cover (11). Secure
with two screws, but do not tighten at this time.

10. Align hole in brake hand lever (17) with hole in master

cylinder bracket. From the top of the assembly, slide pivot
pin (15) through bracket and hand lever.

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

11. Install new retaining ring (18) in pivot pin groove. Verify

that retaining ring is completely seated in groove.

Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and
plunger on the front stoplight switch. (00324a)

HOME

2009 Dyna Service: Chassis 2-39

12. See

Figure 2-65

. Position the brake lever/master cylinder

assembly inboard of the switch housing assembly, enga-
ging the tab (2) on the lower switch housing (1) in the
groove (3) at the top of the brake lever bracket (4).

13. Align the holes in the handlebar clamp with those in the

master cylinder housing and start the two T27 TORX
screws (with flat washers). Position hand lever and controls
for rider comfort. Beginning with the top screw, tighten the
screws to 60-80 in-lbs (6.8-9.0 Nm).

14. Tighten switch housing screws to 35-45 in-lbs (4.0-5.1

Nm).

Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and caliper bore are clean and undamaged before
assembly. (00321a)

15. Start banjo bolt (with new steel/rubber washers) to secure

brake line fitting to master cylinder reservoir. Tighten banjo
bolt to 17-22 ft-lbs (23.1-29.9 Nm).

Use fresh D.O.T. 4 fluid. Contaminated fluid can adversely
affect braking, which could result in death or serious
injury. (00504b)

sm02707

Switch housing assembly

Tab

Groove

Brake lever bracket

Figure 2-65. Attach Master Cylinder to Right Handlebar

Switches

NOTE

The shelf life of a bottle of unopened DOT 4 brake fluid is one
year. The shelf life of an uncontaminated bottle that has been
opened and then resealed is one week.

16. Remove the master cylinder reservoir cover. Stand

motorcycle up so master cylinder is level. Add brake fluid
to master cylinder reservoir until fluid level is 1/4 ± 1/8 in.
(6.35 ± 3.18 mm) from the top.

NOTE

Use only Harley-Davidson DOT 4 BRAKE FLUID, Part No.
99953-99A (12 ounce bottle), from a sealed container.

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. (00288a)

17. Bleed front brake system. See

1.16 BLEEDING BRAKES

18. Verify proper operation of the master cylinder relief port.

Actuate the brake hand lever. A slight spurt of fluid will
break the fluid surface in the reservoir compartment if all
internal components are working properly.

19. Add brake fluid to the master cylinder reservoir until the

fluid level is about 1/4 ± 1/8 in. (6.35 ± 3.18 mm) from the
top.

20. Install the master cylinder reservoir cover and gasket.

Tighten to 6-8 in-lbs (0.7-0.9 Nm).

21. With the Ignition/Light Key Switch turned to IGNITION,

actuate the front brake hand lever to verify operation of
the brake lamp.

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. (00289a)

22. Test ride the motorcycle. If the brake feels spongy, repeat

the bleeding procedure.

NOTE

The sight glass allows a visual check of the brake fluid level
without having to remove the master cylinder reservoir cover.
The sight glass is dark when the reservoir is full, and lightens
as the fluid level drops.

HOME

2-40 2009 Dyna Service: Chassis

2.14

FRONT BRAKE CALIPER

REMOVAL

NOTE

If only replacing brake pads, see

1.17 BRAKE PADS AND

DISCS

Direct contact of D.O.T. 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 D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and caliper bore are clean and undamaged before
assembly. (00321a)

D.O.T. 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 per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

See

Figure 2-66

. Remove the banjo bolt (1) and both

steel/rubber washers (2) to detach front brake line (3) from
caliper. Discard washers.

Remove the upper (4) and lower (5) mounting bolts
(metric). Lift caliper upward to remove from brake disc.

sm03720

Banjo bolt

Steel/rubber washer (2)

Brake line

Upper mounting bolt (long)

Lower mounting bolt (short)

Figure 2-66. Front Caliper

DISASSEMBLY

TOOL NAME

PART NUMBER

FRONT BRAKE CALIPER PISTON
REMOVER

HD-48649

See

Figure 2-67

. Remove bridge bolt/pad pin (12) (metric),

brake pads (7) and bridge bolt (11) (metric) to separate
caliper housings (1, 8).

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2009 Dyna Service: Chassis 2-41

sm03824

Outer caliper housing

Inner caliper housing

Crossover seal

O-ring

10.

Bleeder valve

Square seal (4)

11.

Wiper (4)

Bridge bolt

12.

Bridge bolt/pad pin

Piston (4)

13.

Anti-rattle spring (4)

Upper mounting bolt (long)

14.

Lower mounting bolt (short)

Brake pads (2)

Figure 2-67. Front Brake Caliper

If necessary, remove bleeder valve (10).

. Remove pistons.

Place FRONT BRAKE CALIPER PISTON
REMOVER (Part No. HD-48649) (3) between caliper
housings.

NOTE

Ensure the hole in the tool (1) aligns with the crossover
holes (2) in the caliper housings.

Insert two bridge bolts (2) (metric) and tighten
securely.

If the bleeder valve was removed, install finger-tight.

Apply low pressure compressed air to banjo bolt hole
(1) to remove pistons from caliper bores. Listen for
all four pistons to "pop" against the tool.

Remove bridge bolts and remove tool.

Wiggle pistons from caliper bores to completely remove.

If necessary, remove pad springs from each piston.

Avoid leakage. Prevent damage to piston or piston bore.
Use non-metallic tools when servicing components.
(00529d)

See

Figure 2-70

. Remove and discard crossover seal (1)

from inside caliper housing.

Using a wooden toothpick (2), remove a wiper (3) and
square seal (4) from each caliper bore. Discard all
removed parts.

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2-42 2009 Dyna Service: Chassis

sm03820

Hole in tool

Crossover hole in caliper housing

Figure 2-68. Installing Tool

sm03819

Banjo bolt hole - apply low-pressure air

Bridge bolt (2)

Brake caliper piston remover

Figure 2-69. Removing Pistons

sm03821

Crossover seal

Wooden toothpick

Wiper

Square seal

Figure 2-70. Wipers and Seals

CLEANING, INSPECTION AND REPAIR

Clean all parts with denatured alcohol or D.O.T. 4 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 a wire or similar instrument to clean drilled pas-
sages.

Carefully inspect all components. Replace any parts that
appear damaged or worn.

Check pistons for pitting, scratches or corrosion on
face and also on ground surfaces.

Inspect caliper piston bore. Do not hone bore. If bore
should show pitting or corrosion, replace caliper.

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
0.015 in. (0.38 mm), replace both pins.

Always replace wipers, square seals and crossover
seal after disassembly.

HOME

2009 Dyna Service: Chassis 2-43

If decal on outside housing is removed, scrape remaining
adhesive from surface with a razor blade.

Inspect brake pads and brake disc. See

1.17 BRAKE

PADS AND DISCS

ASSEMBLY

NOTE

Do not use D.O.T. 4 brake fluid for lubrication. Use of D.O.T.
4 brake fluid will result in increased lever travel.

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.

Lubricate nose radius and outside diameter of piston.
Apply lube to inside of caliper piston bores.

Apply lube to inside diameter of seals and wipers.

Avoid leakage. Prevent damage to piston or piston bore.
Use non-metallic tools when servicing components.
(00529d)

See

Figure 2-67

. Install a new square seal (3) and a new

wiper (4) into each piston bore. Use a wooden toothpick
(2) to aid installation if needed.

See

Figure 2-71

. Install pad spring (2) in each piston.

Ensure spring is securely installed in the groove in the
piston.

Turn the piston so the pad spring (2) is oriented as shown.
Carefully insert pistons, by hand, into bores of both caliper
housings. Press pistons squarely into place until they
bottom in the bores. If installation shows resistance,
remove piston and check that seals and wipers are prop-
erly installed.

Place a new crossover seal (1) on inside caliper housing.

Assemble caliper housings.

Install bleeder valve and tighten to 80-100 in-lbs (9.0-
11.3 Nm).

Verify that new crossover seal is installed on inside
caliper housing.

See

Figure 2-67

. Mate inside and outside caliper

housings using bridge bolt (11) and upper mounting
bolt (long) (13) (metric).

Tighten bridge bolt to 28-38 ft-lbs (38.0-51.5 Nm).

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

NOTES

•

See

Figure 2-72

. Ensure the pad spring tabs (1) on brake

pad engage the pad springs in the pistons.

•

If the directional tab (2) does not face down when caliper
is installed, brake noise may develop.

Install new pads into caliper. The directional tab (2) must
face down when caliper is installed.

See

Figure 2-67

. Install pad pin/bridge bolt (12) (metric).

Tighten to 15-16 ft-lbs (20.3-22.6 Nm).

sm03827

Crossover seal

Pad springs

Figure 2-71. Front Caliper Pad Springs

sm04031

Pad spring tabs

Directional tab

Figure 2-72. Front Brake Pad

INSTALLATION

See

Figure 2-73

. Attach caliper to fork leg.

Place caliper over brake disc with bleeder valve facing
upwards.

Loosely install upper mounting bolt (4) (metric) into
top hole on fork leg.

Install lower mounting bolt (5) (metric) into bottom
hole on fork leg. Tighten bottom mounting bolt to 28-
38 ft-lbs (38.0-51.5 Nm).

Final tighten the top mounting bolt to 28-38 ft-lbs
(38.0-51.5 Nm).

HOME

2-44 2009 Dyna Service: Chassis

Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and master cylinder bore are clean and undamaged before
assembly. (00322a)

Lubricate new steel/rubber washers with D.O.T. 4 BRAKE
FLUID. Connect the brake line (3) to caliper using two
new steel/rubber washers (2) and banjo bolt (1). Tighten
to 17-22 ft-lbs (23.1-29.9 Nm).

Remove cover from front brake master cylinder. Fill master
cylinder with D.O.T. 4 BRAKE FLUID. Verify that fluid level
is 1/4 ± 1/8 in. (6.35 ± 3.18 mm) below top of reservoir
with master cylinder in a level position.

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. (00279a)

Bleed brake system. See

1.16 BLEEDING BRAKES

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. (00288a)

Verify proper operation of the master cylinder relief port.
Actuate the brake lever with the cover removed. A slight

spurt of fluid will break the surface if all internal compon-
ents are working properly.

Install gasket and cover on master cylinder. Tighten cover
screws to 6-8 in-lbs (0.7-0.9 Nm).

Turn ignition switch ON. Pump brake hand lever to verify
operation of the brake lamp.

Test ride the motorcycle. If the brakes feel spongy, bleed
the system again. See

1.16 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.

sm03720

Banjo bolt

Steel/rubber washer (2)

Brake line

Upper mounting bolt (long)

Lower mounting bolt (short)

Figure 2-73. Front Caliper

HOME

2009 Dyna Service: Chassis 2-45

2.15

REAR BRAKE MASTER CYLINDER

GENERAL

Do not use parts from single caliper repair kits (9/16 inch
bore) on dual caliper models. Likewise, do not use parts
from dual caliper repair kits (11/16 inch bore) on single
caliper models. Using incorrect parts can cause brake
failure, which could result in death or serious injury.
(00278a)

Do not allow dirt or debris to enter the master cylinder
reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)

REMOVAL

See

Figure 2-74

. Remove banjo bolt (19) and banjo

washers (18). Discard washers.

Remove master cylinder mounting nut (17).

Loosen jam nut (21) on threaded brake rod (22).

Unscrew push rod (9) from brake rod.

NOTE

Wrench flats on push rod allow a wrench to be used if needed.

Raise pedal to move master cylinder/reservoir (12) forward
and out of frame bracket (16).

HOME

2-46 2009 Dyna Service: Chassis

sm02244a

17.

Nut

Push rod

Retaining ring

18.

10.

Washer

Banjo washer (2)

Cartridge body O-ring (2)

11.

19.

Cartridge body

Boot

Banjo bolt

20.

12.

Brake line

Reservoir

Retainer

21.

13.

Spring

Jam nut

Cover gasket

14.

22.

Cover

Retaining ring

Brake rod

23.

15.

Brake pedal

Screw (2)

Retaining ring

16.

Washer

Frame bracket

Figure 2-74. Rear Brake Master Cylinder

DISASSEMBLY

Clean exterior of master cylinder/reservoir with a clean,
nonflammable solvent. Lubricate all internal parts with
lubricant provided in kit.

See

Figure 2-74

. Thread banjo bolt (19) into the cartridge

body (11).

Remove boot (3) from groove in master cylinder/reservoir
(12). Set master cylinder/reservoir upright with banjo bolt

resting on bench and push master cylinder/reservoir down
and off the cartridge body.

Protect cartridge body from dirt or grease.

Press down on large washer (2) to compress spring (5),
keep spring compressed and remove retaining ring (1)
from groove in push rod (9).

Carefully release spring and remove washer, boot, spring
retainer (4) (inside boot) and spring.

HOME

2009 Dyna Service: Chassis 2-47

Remove and discard retaining ring (7) from bore of cart-
ridge body and remove push rod and washer (8).

NOTE

Do not disassemble cartridge body (11). The cartridge body
contains the piston and associated components. These parts
are not sold; therefore, replace the cartridge body if piston seal
leakage is evident.

CLEANING AND INSPECTION

Clean exterior of master cylinder/reservoir with a clean,
nonflammable solvent. Lubricate all internal parts with
lubricant provided in kit.

See

Figure 2-74

. Inspect reservoir bore (12) for scratches.

Replace if scratches are present.

Check boot (3) for tears and replace if any exist.

Inspect threads on cartridge body (11), push rod (9) and
banjo bolt (19). Replace any part with damaged threads.
Inspect spring for cracks or broken coils - replace if any
exist.

Carefully remove large O-rings (10) from cartridge body.
Do not scratch O-ring grooves. Clean grooves with soft
cotton cloth moistened with alcohol. Inspect grooves for
scratches and dirt. Remove dirt or replace cartridge body
if grooves are scratched.

ASSEMBLY

Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and master cylinder bore are clean and undamaged before
assembly. (00322a)

See

Figure 2-74

. Lubricate O-rings (10) with D.O.T. 4

brake fluid and install in O-ring grooves on cartridge body
(11).

Lubricate bore of master cylinder/reservoir (12) with D.O.T.
4 brake fluid.

Insert cartridge body into reservoir. Using hand-pressure
only, press cartridge body into adapter making sure notch
on cartridge body engages lug inside bore of the adapter.

Thread banjo bolt (19) into cartridge body and stand
master cylinder upright with banjo bolt resting on bench.

Place washer (8) on push rod (9).

Place a new retaining ring (7) on push rod. Insert ball-end
of push rod into piston. Push piston downward with push
rod until washer is properly seated in the cartridge bore.

Install the new retaining ring in groove inside cartridge
bore. Make certain retaining ring is fully seated in groove.

Release downward pressure on push rod and check that
push rod rotates freely.

Install retaining ring (6) in groove on cartridge body.

10. Install on push rod, spring (5), spring retaining washer (4)

(large cupped side toward spring), boot (3) with drain hole
down, and washer (2).

11. Press down on washer and install retaining ring (1) in push

rod groove.

12. Seat sealing lip of boot into groove on master cyl-

inder/reservoir adapter.

INSTALLATION

See

Figure 2-74

. Guide threaded end of master cyl-

inder/reservoir (12) through hole in bracket (16). Make
sure the square body of the master cylinder/reservoir is
engaged in the square hole of the mounting bracket.

Install nut (17) and tighten to 30-40 ft-lbs (40.7-54.2 Nm).

Thread push rod (9) fully onto brake rod (22). Do not
tighten jam nut (21) at this time.

Lubricate new steel/rubber washers (18) with D.O.T. 4
BRAKE FLUID. Install brake line (20) using banjo bolt (19)
and new steel/rubber washers (18). Position brake line
and tighten banjo bolt to 21-25 ft-lbs (28.5-33.9 Nm).

When adjusting brake control rod, never allow more than
nine threads to be exposed between control rod and jam
nut. If more than nine threads are exposed, brake rod can
come apart resulting in loss of rear brake, which could
cause death or serious injury. (00306c)

Unscrew push rod from brake rod just enough to adjust
pedal height. When correct pedal height is obtained,
tighten jam nut. Make certain that no more than nine
threads are visible on brake rod.

HOME

2-48 2009 Dyna Service: Chassis

Verify that water drain hole in rubber boot (3), which covers
rear brake push rod, is positioned to bottom.

NOTE

Brake pedal freeplay is built into master cylinder and no
adjustment is required. When pedal is pushed down with hand,
a small amount of freeplay must be felt.

Bleed brake system and tighten bleeder valve as directed.
See

1.16 BLEEDING BRAKES

Install gasket (13) and cover (14) on master cylinder/reser-
voir. Tighten cover screws to 6-8 in-lbs (0.7-0.9 Nm).

Test brake system.

Turn ignition switch ON. Pump brake pedal to verify
operation of the brake lamp.

Test ride the motorcycle. If the brakes feel spongy,
bleed the system again. See

1.16 BLEEDING

BRAKES

NOTE

A sight glass in cover (14) enables the rider to visually check
the brake fluid level without removing the master cylinder cover.
When the reservoir is full, the sight glass appears dark. As the
fluid level drops, the glass appears lighter to indicate this con-
dition to the rider.

HOME

2009 Dyna Service: Chassis 2-49

2.16

REAR BRAKE CALIPER

REMOVAL

NOTE

If only replacing brake pads, do not remove rear brake caliper.
Should pad replacement be necessary, see

1.17 BRAKE PADS

AND DISCS

Remove right saddlebag, if equipped.

See

Figure 2-75

. Remove the banjo bolt (1) and both

steel/rubber washers (2) to detach rear brake line from
caliper. Discard washers.

Remove both the slider pin (3) and mounting bolt (4)
(metric). Remove caliper assembly from brake disc.

To remove rear caliper mount:

Remove axle from rear wheel. See

2.5 REAR

WHEEL

Lift rear caliper mount away from axle and rear fork.
Notch in caliper mount must clear tab on rear fork.

sm03721

Banjo bolt

Steel/rubber washer (2)

Slider pin

Mounting bolt

Tab slot

Figure 2-75. Rear Caliper

DISASSEMBLY

TOOL NAME

PART NUMBER

BRAKE CALIPER PISTON REMOVER

HD-48648

See

Figure 2-76

. Remove pad pin (3) and brake pads (12).

If necessary, remove bleeder valve (4).

NOTE

If phenolic insulators (8) are loose, remove from pistons.

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2-50 2009 Dyna Service: Chassis

sm03836

Torque clip

Slider pin

10.

Bushing (upper)

Rear caliper mount

11.

Rubber bumper

Pad pin

12.

Bleeder valve with o-ring

Brake pads (2)

13.

Anti-rattle spring

Caliper housing

14.

Square seals (4)

Rubber boot

15.

Bushing (lower)

Piston (2)

16.

Phenolic insulator (available only in repair kit)

Mounting bolt

Figure 2-76. Rear Brake Caliper

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.
(00530b)

NOTE

Phenolic insulators may be loose when the brake pads are
removed, or may loosen when the pistons are expanded from
their bores. If insulators are not damaged, they can be reused.

See

Figure 2-77

. Remove pistons.

Place BRAKE CALIPER PISTON REMOVER (Part
No. HD-48648) (3) into caliper housing. Install bolt
(2) only enough to hold tool in place.

NOTE

Tool retaining bolt (2) is used only to keep tool from slip-
ping out of the caliper during piston removal, and does
not need to be tight. Do not use a wrench to tighten.

If the bleeder valve was removed, install it finger-tight.

HOME

2009 Dyna Service: Chassis 2-51

Apply low pressure compressed air to banjo bolt hole
(1) to remove pistons from caliper bores. Listen for
both pistons to "pop" against the tool.

Remove piston remover tool.

Wiggle pistons from caliper bores to completely remove.

Avoid leakage. Prevent damage to piston or piston bore.
Use non-metallic tools when servicing components.
(00529d)

See

Figure 2-78

. Using a wooden toothpick (1), remove

two square seals (2) from each caliper bore. Discard all
removed parts.

Pull anti-rattle spring (3) straight out to remove.

sm03834

Banjo bolt hole - apply low-pressure air

Remover retaining bolt

Brake caliper piston remover (Part No. HD-48648)

Figure 2-77. Removing Pistons

sm03833

Wooden toothpick

Square seal

Anti-rattle spring

Figure 2-78. Seals and Spring

CLEANING, INSPECTION AND REPAIR

HOME

2-52 2009 Dyna Service: Chassis

Carefully inspect all components. Replace any parts that
appear damaged or worn.

Check pistons for pitting, scratches or corrosion on
face and also on ground surfaces.

Inspect phenolic insulators for damage.

Inspect caliper piston bore. Do not hone bore. If bore
should show pitting or corrosion, replace caliper.

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
0.015 in. (0.38 mm), replace both pins.

See

Figure 2-76

. Inspect rubber boot (14) for cracks

and damage. Inspect bushing (15) for free movement.
Inspect bushing (2) for free movement or damage.

Always replace square seals after disassembly.

If decal on outside housing is removed, scrape remaining
adhesive from surface with a razor blade.

Inspect brake pads and brake disc. See

1.17 BRAKE

PADS AND DISCS

ASSEMBLY

NOTE

Do not use D.O.T. 4 brake fluid for lubrication. Use of D.O.T.
4 brake fluid will result in increased lever travel.

Lubricate nose radius and outside diameter of piston.
Apply lube to inside of caliper piston bores.

Apply lube to inside diameter of square seals.

Avoid leakage. Prevent damage to piston or piston bore.
Use non-metallic tools when servicing components.
(00529d)

See

Figure 2-78

. Install two new square seals (2) into

each piston bore. Use a wooden toothpick (1) to aid
installation if needed.

Install anti-rattle spring (3). Ensure it is oriented correctly.

Carefully insert pistons, by hand, into bores of caliper
housing. Press pistons squarely into place until they
bottom in the bores. If installation shows resistance,
remove piston and check that seals are properly installed.

See

Figure 2-76

. Install bleeder valve (4) (with o-ring) in

caliper housing, if removed, and tighten to 80-100 in-lbs
(9.0-11.3 Nm).

NOTE

Ensure phenolic insulators (8) are in place before installing
brake pads.

Insert brake pads into caliper with friction material facing
opening for brake disc.

Install pad pin (3) and tighten to 80-120 in-lbs (9.0-13.6
Nm).

NOTE

If pad pins do not fit, check the following:

•

You are using a set of pads, not two identical pads.

•

Anti-rattle spring orientation matches

Figure 2-76

INSTALLATION

Install rear axle and caliper mount if removed. Ensure
notch in mount engages tab on rear fork. See

2.5 REAR

WHEEL

See

Figure 2-76

. Ensure torque clip (9) is in place in cal-

iper mount.

See

Figure 2-75

. Install caliper with pads on caliper mount.

Tighten slider pin (3) and mounting bolt (4) (metric) to 10-
14 ft-lbs (13.6-18.9 Nm). Ensure tabs on brake pads
engage slot (5) in caliper mount.

Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and caliper bore are clean and undamaged before
assembly. (00321a)

Lubricate new steel/rubber washers with D.O.T. 4 BRAKE
FLUID. Connect the brake line to caliper using two new
washers (2) and banjo bolt (1). Tighten to 21-25 ft-lbs
(28.5-33.9 Nm).

Remove cover from rear brake master cylinder. Fill master
cylinder with D.O.T. 4 BRAKE FLUID. Verify that fluid level
is 1/4 ± 1/8 in. (6.35 ± 3.18 mm) below top of reservoir
with master cylinder in a level position.

Bleed brake system. See

1.16 BLEEDING BRAKES

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2009 Dyna Service: Chassis 2-53

Test brake system.

Turn ignition switch ON. Pump brake foot pedal to
verify operation of the brake lamp.

Test ride the motorcycle. If the brakes feel spongy,
bleed the system again. See

1.16 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.

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