Harley Davidson Sportster Models 2009. Service Repair Manual — page 20

2-38 2009 Sportster Service: Chassis

2.8

TRUING LACED WHEELS

GENERAL

The rim must be trued both laterally and radially. If new bear-
ings were installed, wheels may be trued with only the bearings
and center spacer installed.

LATERAL TRUING

TOOL NAME

PART NUMBER

SPOKE WRENCH

HD-94681-80

WHEEL TRUING STAND

HD-99500-80

Figure 2-59

. With a piece of tape, mark the center of

each of four groups of four as shown. The groups should
be directly across from one another and approximately
90° apart.

sm01235

Figure 2-59. Marking Spoke Groups

NOTE

All Harley-Davidson laced wheels use a cross-4 pattern. Each
outer spoke must cross four inner spokes before entering rim
hole.

Finger tighten the spokes in these four groups. Leave all
other spokes loose.

Install truing arbor in wheel hub and place wheel in
WHEEL TRUING STAND (Part No. HD-99500-80).Tighten
arbor nuts so hub will turn on its bearings.

NOTE

16 inch (rear) and 21 inch (front) chrome aluminum profile
laced wheels are optional for XL 883C and XL 1200C models.
The offset measurement for positioning the profile wheel is
shown in

Figure 2-60

sm01800

Figure 2-60. Positioning Chrome Aluminum Profile Laced

Wheel Hub

sm01801

Figure 2-61. Positioning 16 Inch Wheel Hub

2009 Sportster Service: Chassis 2-39

See

Figure 2-61

. See

Figure 2-62

. Refer to

Table 2-21

The hub must be positioned correctly with the rim. Lay a
straightedge across the primary hub brake disc mounting
face and the rim. Measure the distance from the
straightedge to the rim as shown. If this dimension does
not match the dimension listed in the table, loosen and
tighten the four spokes accordingly. Use SPOKE
WRENCH (Part No. HD-94681-80).

NOTE

See

Figure 2-61

. See

Figure 2-62

. Refer to

Table 2-21

Dimension "A" must be maintained to ensure centering of wheel
on motorcycle.

EXAMPLE

If dimension A on the left side is not correct, loosen the two
spokes attached to the hub left side and tighten the two spokes
attached to the hub right side. Turn all four spokes an equal
number of turns until dimension is equal to within 0.040 in.
(1.02 mm) for both sides.

NOTE

Always loosen the appropriate two spokes before tightening
the other two. Reversing this procedure will cause the rim to
become out-of-round.

Repeat the previous step for all four groups on the wheel.

Table 2-21. Hub Positioning Dimensions

DIMENSION A VALUE

RIM

IN.

SIZE

TYPE

37.39-37.90

1.472-1.492

16 in.

Steel laced

21.26-21.77

0.837-0.857

19 in.

18.26-18.77

0.719-0.739

21 in.

30.17-30.67

1.188-1.207

16 in.

Chrome alu-
minum profile
laced

19.03-19.53

0.749-0.769

21 in.

19 in.

21 in.

sm01236

Figure 2-62. Centering 19 Inch and 21 Inch Hub

RADIAL TRUING

See

Figure 2-63

. Adjust truing stand gauge to the rim's

tire bead seat as shown. The rim should be trued within
0.030 in. (0.76 mm).

NOTES

•

Tighten or loosen spoke one flat at a time and recheck
measurement.

•

Always loosen the appropriate spokes before tightening
the other two. Reversing this procedure will cause the rim
to become out-of-round.

2-40 2009 Sportster Service: Chassis

Spin the rim slowly.

If the rim contacts the gauge on or near a marked
group of spokes, loosen the spokes in the marked
group on the opposite side of the rim. Now tighten
the spokes in the group where the rim makes contact.
Loosen and tighten spokes an equal number of turns.

If the rim contacts the gauge between two marked
groups, loosen the spokes in both opposite groups
and tighten the spoke groups on the side of the rim
that makes contact.

When the wheel is centered and trued, start at the valve
hole and tighten the rest of the spoke nipples one turn at
a time until they are snug.

Seat each spoke head in the hub flange using a flat nose
punch and mallet. Then check wheel trueness again and
tighten the nipples accordingly.

Spokes that are too tight can draw nipples through the rim
or distort hub flanges. Spokes that are too loose can
continue to loosen when put in service. Either condition
can adversely affect stability and handling, which could
result in death or serious injury. (00286a)

Verify spokes are tightened to specification listed in

Table 2-22

File or grind off ends of spokes protruding through nipples
to prevent puncturing tube when tire is mounted.

NOTE

After installation of front wheel, visually check the relationship
of the front wheel to the fork fender bosses. The front wheel
should be approximately centered between the bosses.

sm02464

Figure 2-63. Truing Rim Radially

Table 2-22. Spoke Nipple Torque Specification

MINIMUM TORQUE

RIM TYPE

55 in-lbs (6.2 Nm)

All

2009 Sportster Service: Chassis 2-41

2.9

CHECKING CAST WHEEL RUNOUT

GENERAL

The die-cast wheels should be checked for lateral and radial
runout before installing a new tire or tube.

LATERAL RUNOUT

Figure 2-64

. Install arbor in the wheel hub and place wheel

in the truing stand. To check rim lateral runout, place a gauge
rod or dial indicator near the rim bead. If lateral runout exceeds
0.030 in. (0.76 mm), replace the wheel.

sm03115

Wheel truing and balancing stand

Lateral runout

Gauge rod

Figure 2-64. Checking Cast Wheel Lateral Runout

RADIAL RUNOUT

TOOL NAME

PART NUMBER

WHEEL TRUING AND BALANCING
STAND

HD-99500-80

See

Figure 2-65

. Using WHEEL TRUING AND BALANCING

STAND (Part No. HD-99500-80), check for radial runout as
shown. Replace the wheel if runout exceeds 0.030 in. (0.76
mm).

sm03726

Wheel truing and balancing stand

Radial runout

Gauge rod

Figure 2-65. Checking Cast Wheel Radial Runout

2-42 2009 Sportster Service: Chassis

2.10

FRONT BRAKE MASTER CYLINDER

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.

2.11 FRONT BRAKE CALIPER: XL MODELS

Figure 2-66

. The bore size is cast into the side of the

master cylinder body facing the handlebar.

•

The single disc master cylinder has "11" (11 mm) cast into
the body.

•

The dual disc master cylinder has "1/2" (1/2 in.) cast in.

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)

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)

NOTE

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

INSPECTION

Check the level of fluid in the front brake reservoir. If it is
low, refill and bleed brake system. See

1.8 BLEEDING

HYDRAULIC BRAKE SYSTEM

Check for fluid leaks in the brake line, around banjo fittings
or front brake caliper pistons or bleeder valve. Repair and
bleed brake system.

For brake line replacement procedure, see

2.18 BRAKE LINES

To repair front brake caliper, see procedure in

2.12 FRONT BRAKE CALIPER: XR MODELS

See

1.8 BLEEDING HYDRAULIC BRAKE SYSTEM

for hydraulic brake system bleeding procedure.

Check front brake friction pads and disc(s) for excessive
wear or damage. Replace worn or damaged items.

1.9 BRAKE PADS AND DISCS: XL MODELS

1.10 BRAKE PADS AND DISCS: XR MODELS

for

specifications and brake pad replacement procedure.

2.4 WHEELS

for brake disc replacement pro-

cedure.

Eliminate any air in the hydraulic brake assembly by
bleeding the system. See

1.8 BLEEDING HYDRAULIC

BRAKE SYSTEM

If none of these conditions exist but the front brake system
does not operate properly, the front brake master cylinder is
most likely defective and must be repaired or replaced.

REMOVAL

Figure 2-67

. Loosen turn signal clamp screw (3) and

remove turn signal assembly (5) from front brake master
cylinder housing (1).

Loosen and remove lock nut and washer (4), and lift mirror
(2) from master cylinder housing.

sm01237

Figure 2-66. Verifying Front Brake Master Cylinder Bore

Size (Single Disc Master Cylinder Shown)

sm01238

Front brake master cylinder and reservoir

Mirror

Turn signal clamp screw

Lock nut and washer

Turn signal assembly

Front brake banjo fitting

Banjo bolt

Washer (2)

Figure 2-67. Front Brake Master Cylinder (typical: XL model

shown)

2009 Sportster Service: Chassis 2-43

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)

Figure 2-68

. See

Figure 2-69

. Remove bleeder nipple

cap (2) from bleeder valve (3) on front brake caliper (1).
Install end of a length of 5/16 in. (7.9 mm) I.D. clear plastic
tubing over caliper bleeder valve (3), while placing free
end in a suitable container. Open bleeder valve about 1/2
turn. Pump brake hand lever several times to drain brake
fluid. Close bleeder valve.

sm01239

Front brake caliper

Bleeder nipple cap

Bleeder valve

Figure 2-68. Front Caliper Bleeder Valve (typical; XL

shown)

sm01424

Figure 2-69. Bleeding Hydraulic System (typical; XL model

shown)

Figure 2-67

. Remove banjo bolt (7) and two washers

(8) to disconnect hydraulic brake line banjo fitting (6) from
master cylinder (1). Discard washers.

Figure 2-70

. Squeeze front brake lever and place a

5/32 in. (4 mm) thick cardboard insert between brake lever
and lever bracket. Release brake lever.

sm01240

Figure 2-70. Install Cardboard Insert Before Removing

Master Cylinder Assembly

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)

NOTE

Use the eyelet of an ordinary cable strap if the cardboard insert
is not available.

2-44 2009 Sportster Service: Chassis

. Using a T-27 TORX drive head, remove

the two screws (6) and washers (7) securing the handlebar
clamp (8) to the master cylinder housing (5). Remove the
brake lever/master cylinder assembly and clamp from the
handlebar.

DISASSEMBLY

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)

NOTE

Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.

See

. Remove retaining ring (17) from pivot

pin (9) groove at bottom of master cylinder bracket. Dis-
card retaining ring.

Remove pivot pin and brake hand lever (18) from master
cylinder assembly.

Remove and discard dust boot (16).

NOTE

See

Figure 2-72

. Clamp front brake master cylinder in a vise

by the mirror mounting boss only. Use brass or aluminum jaw
covers or other protective device on vise jaws to prevent
damage to master cylinder.

See

Figure 2-72

. Clamp master cylinder in a vise so that

banjo fitting hole is pointing straight down.

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)

NOTE

Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.

See

. Press down on end of piston and remove

retaining ring (15). Discard retaining ring.

Single disc piston assembly: remove stop plate (22).

Remove and discard piston assembly (12, 13, 14) and
piston spring (11).

NOTES

•

See

Figure 2-71

. Both primary (12) and secondary (13)

cups are fitted into grooves in the piston body (14). The
piston spring (11) fits onto the end of the piston.

•

To prevent dirt and other contaminants from entering the
master cylinder reservoir, thoroughly clean the cover
before removal

Remove two screws (1), cover (2), diaphragm plate (3)
and diaphragm (4) from the master cylinder reservoir.

2009 Sportster Service: Chassis 2-45

sm02388

13.

Secondary cup*

Screw (2)

14.

Reservoir cover

Piston*

15.

Retaining ring*

Diaphragm plate

16.

Diaphragm

Dust boot*

17.

Retaining ring

Master cylinder housing

18.

Screw (2)

Brake hand lever

19.

Bushing

Washer (2)

20.

Handlebar clamp

G40M brake grease*

21.

CCI #20 brake grease*

Pivot pin

10.

22.

Brake line banjo fitting seating surface

Stop plate (single disc piston only)*

23.

11.

Single disc piston assembly

Spring*

12.

24.

Primary cup*

Dual disc piston assembly

Figure 2-71. Front Brake Master Cylinder Assembly (*Provided in Service Parts Kit)

2-46 2009 Sportster Service: Chassis

sm01241

Figure 2-72. Clamping Front Master Cylinder

CLEANING, INSPECTION AND REPAIR

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 brake system components with denatured
alcohol. Do not contaminate with mineral oil or other
solvents. Wipe dry with a clean, lint free cloth. Blow out
drilled passages and piston bore with low pressure com-
pressed air from a clean air supply. Do not use a wire or
similar instrument to clean drilled passages in bottom of
reservoir.

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)

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
banjo fitting. This is a critical sealing surface. Replace
the housing if you find any scratches, dents or other
damage.

Inspect diaphragm for cuts, tears or general deterior-
ation. Replace if necessary.

ASSEMBLY

NOTES

•

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

•

CCI #20 BRAKE GREASE is recommended for lubrication
of cylinder bore, cups and seals prior to assembly.

•

See

Figure 2-72

. Clamp front brake master cylinder in a

vise by the mirror mounting boss only. Use brass or alu-
minum jaw covers or other protective device on vise jaws
to prevent damage to master cylinder.

See

Figure 2-72

. Clamp master cylinder in a vise so that

banjo fitting hole is pointing straight down.

See

. Coat piston bore of master cylinder

housing (5), piston (14), primary cup (12) and secondary
cup (13) with CCI #20 BRAKE GREASE (21) supplied in
the service parts kit.

See

Figure 2-73

. Install piston assembly into master cyl-

inder.

Press small end of piston spring (4) onto mounting
boss (6) on piston (1).

Slide piston/spring assembly, flared end of spring first,
into master cylinder bore so that spring seats against
counter bore (recess) at bottom of cylinder.

Single disc piston: Slide stop plate (7) down over
end of piston.

sm02406

Piston

Primary cup

Secondary cup

Piston spring

Dust boot groove

Piston spring mounting boss

Stop plate (single disc piston only)

Figure 2-73. Front Brake Master Cylinder Piston

(Typical-Single Disc Piston Shown)

2009 Sportster Service: Chassis 2-47

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)

NOTE

Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.

Dual disc master cylinder: Press down on piston
(14) and install new retaining ring (15). Verify that
retaining ring is fully seated in groove.

Single disc master cylinder: Press down on piston
(14) and stop plate (22), and install new retaining ring
(15). Verify that retaining ring is fully seated in groove.

Install new dust boot (16). Large lip of dust boot fits down
inside end of piston bore. Small lip of dust boot fits into
groove in end of piston (item 5,

Figure 2-73

Apply approximately 0.1 g G40M BRAKE GREASE (from
service parts kit) to each of the following two locations:

Pivot hole in brake hand lever (18).

End of piston (14).

Align hole in brake hand lever with hole in master cylinder
bracket. From top of assembly, slide pivot pin (9) 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)

NOTE

Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.

Install new retaining ring (17) in pivot pin groove. Verify
that retaining ring is fully seated in groove.

Remove master cylinder assembly from vise. Install cover
(2), diaphragm plate (3) and diaphragm (4) on master
cylinder reservoir. Install two screws (1) to fasten cover
to reservoir, but do not tighten at this time.

10. See

Figure 2-74

. Squeeze front brake lever and place a

5/32 in. (4 mm) thick cardboard insert between brake lever
and lever bracket. Release brake lever.

sm01242

Figure 2-74. Install 5/32 in. (4 mm) Cardboard Insert Before

Installing Master Cylinder Assembly

INSTALLATION

Figure 2-75

. Position brake lever/master cylinder

assembly inboard of switch housing assembly (1) engaging
tab (5) on lower switch housing in slot (4) at top of brake
lever bracket (3).

See

. Align holes in handlebar clamp (8) with

those in master cylinder housing (5) and start two screws
(6) with washers (7). Beginning with top screw, tighten
screws to 108-132 in-lbs (12.2-14.9 Nm) using a T27
TORX drive head.

2-48 2009 Sportster Service: Chassis

sm01243

Switch housing assembly

5/32 in. (4 mm) cardboard insert

Brake lever bracket

Slot

Tab

Figure 2-75. Fitting Brake Lever/Master Cylinder To Right

Handlebar Switch Housing

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

NOTE

Master cylinder housings have various positive stops for banjo
fittings, based on the model being repaired. The front brake
systems as used on XR models and XL models employ different
master cylinder housings as shown in

Figure 2-76

. Never

intermix system components. When tightening the banjo bolt
in the next step, ensure the banjo fitting is properly oriented
and contacts the positive stop.

Figure 2-77

. Position a new washer (8) on each side

of hydraulic brake line banjo fitting (6). Insert banjo bolt
(7) through washers and fitting. Thread bolt into master
cylinder housing. Tighten to 20-25 ft-lbs (27.1-33.9 Nm).

sm05497

XR Models master cylinder

XL Models master cylinder

Figure 2-76. Front Brake Master Cylinder Identification

sm01238

Front brake master cylinder and reservoir

Mirror

Turn signal clamp screw

Lock nut and washer

Turn signal assembly

Front brake banjo fitting

Banjo bolt

Washer (2)

Figure 2-77. Front Brake Master Cylinder (typical: XL model

shown)

Position motorcycle so that top of master cylinder reservoir
is level. See

. Remove two screws (1), front

master cylinder reservoir cover (2), diaphragm plate (3)
and diaphragm (4).

NOTES

•

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

•

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.

•

See

Figure 2-78

. Do not use sight glass (2) to determine

maximum fluid level. Sight glass should only be used as
a visual indicator that fluid level is low and needs attention.

2009 Sportster Service: Chassis 2-49

A ridge (1) is cast into the inside of the reservoir to assist
you in determining the correct maximum fluid level.

•

Fill master cylinder only with HARLEY-DAVIDSON D.O.T.
4 BRAKE FLUID from a sealed container.

•

Do not overfill reservoir. Do not reuse old brake fluid.

Figure 2-78

. Add enough HARLEY-DAVIDSON D.O.T.

4 BRAKE FLUID to reservoir to bring fluid level even with
ridge (1) cast into inside of reservoir, about 1/4 in. (6.35
mm) below top edge.

sm01244

Cast-in ridge

Sight glass

Figure 2-78. Filling Front Master Cylinder Reservoir

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 master cylinder relief port. Slowly
actuate brake hand lever with reservoir cover removed. A
slight spurt of fluid will break fluid surface in reservoir
compartment if all internal components are working prop-
erly.

See

Figure 2-79

. Install length of 5/16 in. (7.9 mm) I.D.

clear plastic tubing over front brake caliper bleeder valve
(3). Place free end of tube in a clean container.

sm01424

Figure 2-79. Bleeding Hydraulic System (typical; XL model

shown)

Figure 2-78

. Add enough HARLEY-DAVIDSON D.O.T.

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.

Depress and hold brake hand lever to build up hydraulic
pressure.

10. Open front caliper bleeder valve about 1/2-turn. Brake

fluid will flow from bleeder valve through tubing. Close
bleeder valve when brake hand lever has moved approx-
imately 1/2 to 3/4 of its full range of travel. Allow brake
hand lever to return slowly to its released position.

11. Repeat three previous steps until all air bubbles are

purged.

12. Final tighten bleeder valve to 35-61 in-lbs (4.0-6.9 Nm).

Install bleeder nipple cap.

NOTE

On models with two front brake calipers, repeat steps 7-12 on
second caliper.

13. See

Figure 2-78

. Add enough HARLEY-DAVIDSON D.O.T.

4 BRAKE FLUID to reservoir to bring fluid level even with
ridge (1) cast into inside of reservoir, about 1/4 in. (6.35
mm) below top edge.

14. See

. Note that angular shape of master cyl-

inder cover (2) makes one side thicker than the other.
Install cover with diaphragm plate (3) and diaphragm (4)
on master cylinder housing (5) so that thicker side is
positioned above brake line banjo fitting. Fasten cover to
reservoir with two screws (1). Tighten to 9-17 in-lbs (1.0-
2.0 Nm).

15. See

Figure 2-77

. Install mirror (2), secure with lock nut

and washer (4). Position mirror for best rearward visibility.
Tighten lock nut to 96-144 in-lbs (10.9-16.3 Nm).

16. Install turn signal assembly (5). Position so turn signal

lens faces directly forward and turn signal does not strike
fuel tank when handlebars are turned full right. Tighten
clamp screw (3) to 96-120 in-lbs (10.9-13.6 Nm).

2-50 2009 Sportster Service: Chassis

17. With Ignition/Light Key Switch turned to IGNITION, actuate

front brake hand lever to verify operation of rear 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)

18. Test ride motorcycle at low speed. If brake feels spongy,

repeat bleeding procedure.

2009 Sportster Service: Chassis 2-51

2.11

FRONT BRAKE CALIPER: XL MODELS

REMOVAL

NOTE

If only replacing brake pads, do not remove front brake cal-
iper(s). For brake pad replacement only, see

1.9 BRAKE PADS

AND DISCS: XL MODELS

NOTE

Damaged banjo bolt surfaces will leak when reassembled.
Prevent damage to seating surfaces by carefully removing
brake line components.

NOTE

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

See

Figure 2-80

. Remove bleeder nipple cap (9) from

bleeder valve (8) on front brake caliper (4).

See

Figure 2-81

. Install end of a length of 5/16 in. (7.9

mm) I.D. 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.

See

Figure 2-80

. Remove the banjo bolt (1) and both

washers (2) to detach front brake line (3) from caliper (4).
Discard washers.

Remove pad pin plug (7).

Figure 2-82

. Loosen, but do not remove, brake pad

pin.

See

Figure 2-80

. Remove both mounting bolts (6) (12

pt/10 mm). Pull caliper and mounting bracket assembly
rearward to disengage from brake disc.

sm01333

Banjo bolt

Washer (2)

Front brake line

Brake caliper

Caliper mounting bracket

Mounting bolt (2) (12 pt/10 mm)

Pad pin plug

Bleeder valve

Bleeder nipple cap

Figure 2-80. Front Caliper Assembly

sm01424

Figure 2-81. Bleeding Hydraulic System (typical; XL model

shown)

2-52 2009 Sportster Service: Chassis

sm01334

Figure 2-82. Brake Pad Pin (Plug Removed)

DISASSEMBLY

Figure 2-83

. Remove brake pad pin (14) and brake

pads (8) from caliper body (15).

Slide brake caliper off mounting bracket (1).

Remove pad spring (16). Do not remove bleeder valve
(10) at this time.

Figure 2-84

. Install a discarded brake pad in the cal-

iper (1) with the backing plate (4) facing the pistons. Posi-
tion the brake pad so the friction material (3) is against
the back of the caliper, as shown.

Loosely install brake pad pin (2) to hold brake pad in place.

NOTE

Be careful not to damage banjo bolt sealing surface or threads
of banjo bolt hole in brake caliper. It is recommended that you
use an air nozzle with a rubber tip to perform the next step in
this procedure.

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)

See

Figure 2-85

. Gently apply low pressure compressed

air to banjo bolt hole (3) to force pistons from caliper bores.

Remove brake pad pin and brake pad.

Figure 2-83

. 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.

See

Figure 2-86

. Using a wooden toothpick (1), remove

dust seal (2) and piston seal (3) from each caliper bore.
Discard seals.

10. See

Figure 2-83

. If necessary, remove bleeder valve (10).