Harley Davidson Sportster Models 2009. Service Repair Manual — page 22
passages and piston bore in master cylinder body with
low pressure compressed air from a clean air supply. Do
not use a wire or similar instrument to clean drilled pas-
sages.
2.
Carefully inspect all parts for wear or damage and replace
as necessary.
a.
Inspect piston bore in master cylinder housing for
scratches, grooves, scoring, pitting or corrosion.
Replace housing if any of these conditions are found.
b.
Inspect outlet port that mates with brake line banjo
fitting. This is a critical sealing surface. Replace
housing if any scratches, dents or other damage is
found.
3.
Verify that vent holes in master cylinder are completely
open and free of dirt or debris.
ASSEMBLY
NOTES
•
When assembling rear brake master cylinder, always use
new parts from the service parts kit. Consult the PARTS
CATALOG for the correct kit part number.
•
CCI #20 BRAKE GREASE is recommended for lubrication
of cylinder bore, cups and seals prior to assembly.
•
Stand master cylinder on wooden block or clean, lint-free
towel to protect seating surfaces.
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.
1.
. Coat new o-ring (20) with HARLEY-
DAVIDSON D.O.T. 4 BRAKE FLUID. Install o-ring and
feed port fitting (21) into feed port on top of master cylinder
(19). Secure with new retaining ring (22). Verify that
retaining ring is fully seated in groove.
2.
Slide dust cover (23) onto feed port fitting and press into
place in master cylinder feed port. See
. Turn
feed port fitting (4) so it points toward banjo fitting (5) end
of master cylinder body (1).
2
4
5
1
3
sm01809
1.
Rear master cylinder assembly
2.
External boot
3.
Tabs (2)
4.
Feed port fitting
5.
Banjo fitting hole
Figure 2-106. Assembled Rear Master Cylinder
NOTE
See
. Clamp rear brake master cylinder (19) in a
vise by its mounting bosses (18) only. Use brass jaw covers
or other protective device on vise jaws to prevent damage to
master cylinder.
3.
Clamp master cylinder in a vise with banjo fitting end
pointing down.
4.
. Lubricate master cylinder bore, new
piston (1) with new secondary cup (3), and new primary
cup (2) with CCI #20 BRAKE GREASE supplied in the
service parts kit.
Wear safety glasses or goggles when removing or
installing spring. Spring tension can cause spring,
attached components and/or hand tools to fly out which
could result in death or serious injury. (00477c)
5.
Press small end of new piston spring (4) onto mounting
boss (8) on piston (1).
2-70 2009 Sportster Service: Chassis
1
2
3
4
5
6
7
8
sm02308
1.
Piston
2.
Primary cup
3.
Secondary cup
4.
Piston spring
5.
Push rod
6.
Boot collar nut
7.
Push rod retainer
8.
Piston spring mounting boss
Figure 2-107. Rear Master Cylinder Piston, Push Rod and
Spring Assembly
6.
Slide piston/spring assembly, flared end of spring first,
into cylinder bore so that spring seats against counter bore
(recess) at bottom of cylinder.
7.
Apply approximately 0.1 g of G40M BRAKE GREASE to
ball end of push rod (5). Insert ball end of push rod into
cupped end of piston.
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.
8.
See
. Temporarily thread shoulder nut (4)
onto push rod (13) several turns to protect push rod
threads. Press down on push rod to compress piston
spring (17). Slide push rod retainer (11) down into master
cylinder bore.
9.
Secure push rod assembly with new retaining ring (10).
Verify that retaining ring is fully seated in groove. Remove
shoulder nut from push rod.
10. See
. Apply approximately 0.1 g of G40M
BRAKE GREASE around groove (4) in boot collar nut (3).
Carefully slide inner boot (5) down onto push rod (2) and
into end of master cylinder bore. Press lip of inner boot
down around groove in boot collar nut.
11. See
. Install external return spring (7) and
spring retainer (6). Thread shoulder nut (4) shoulder-first
onto push rod (13), several turns past flats.
12. Thread yoke (3) onto push rod, at least 2-3 turns past flats.
Install new spring pin (12) into end of push rod.
2
4
1
3
5
sm01810
1.
Rear brake master cylinder assembly
2.
Push rod
3.
Boot collar nut
4.
Groove
5.
Inner boot
Figure 2-108. Lubricating and Installing Inner Boot
13. See
. Measure distance from centerline of
clevis pin hole (1) in yoke to centerline of master cylinder
mounting boss hole (2) closest to yoke. This distance must
be 3.40-3.48 in. (86.3-88.3 mm). Turn yoke on push rod
in one direction or the other until this distance is obtained.
NOTE
. Grip yoke by the edges with adjustable
wrench. do not grip yoke by the flats of the yoke may become
deformed.
14. See
. Holding yoke with an adjustable wrench,
turn shoulder nut back against yoke. Tighten to 130-173
in-lbs (14.7-19.6 Nm).
15. Remove master cylinder assembly from vise. See
. Slide external boot (2) over yoke/push rod
assembly and external return spring.
16. Position external boot so that tabs (3) are at the 3-o'clock
and 9-o'clock position when master cylinder body (1) is
held upright. This assures that drain hole is at bottom of
boot when master cylinder is mounted on motorcycle.
Make sure that lip on large end of external boot fits fully
in groove in end of master cylinder. Make sure that spring
retainer is fully seated in groove in small end of external
boot.
2009 Sportster Service: Chassis 2-71
3
1
2
sm01811
1.
Clevis pin hole
2.
Mounting boss hole
3.
3.40-3.48 in. (86.3-88.3 mm)
Figure 2-109. Adjusting Push Rod Length
INSTALLATION
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.
1.
. If master cylinder mounting bracket (15)
was removed:
a.
Attach mounting bracket to frame loosely with screws
(23, 24). Then tighten two screws (23) to 17-22 ft-lbs
(23.1-29.9 Nm). Tighten screw (24) to 17-22 ft-lbs
(23.1-29.9 Nm).
b.
Install bell crank (12) with clevis pin (13). Secure with
new retaining ring (14).
2.
Install rear master cylinder assembly (6) on mounting
bracket (15) with screws (7) and washers (8). Tighten to
17-22 ft-lbs (23.1-29.9 Nm).
3.
Fit yoke (10) onto bell crank (12). Install clevis pin (9) and
secure with new retaining ring (11).
NOTE
Master cylinder housing has a positive stop for banjo fitting.
When tightening banjo bolt into master cylinder in the next
step, rotate banjo fitting clockwise until it contacts positive stop.
4.
Position a new washer (16) on each side of hydraulic
brake line banjo fitting (17). Insert banjo bolt (18) through
washers and fitting. Thread bolt into master cylinder
housing. Tighten to 20-25 ft-lbs (27.1-33.9 Nm).
5.
Install rear brake master cylinder feed hose (3) on master
cylinder feed hose port fitting (5). Secure with new hose
clamp (4). See
2.15 REAR BRAKE MASTER CYLINDER
.
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)
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)
NOTES
•
If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.
•
Rear brake master cylinder reservoir must be in a level
position when filling and checking fluid level.
•
Reservoir cover may be removed from rear brake master
cylinder reservoir to more easily verify fluid level in reser-
voir.
•
Use only HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID
from a sealed container.
•
Do not overfill reservoir. Do not reuse old brake fluid.
6.
Position motorcycle upright (not resting on jiffy stand).
7.
See
. Remove reservoir cap (4). If desired,
remove reservoir cover: grasp cover (2) and gently pull
straight out from reservoir (1).
8.
Fill rear master cylinder reservoir with HARLEY-DAV-
IDSON D.O.T. 4 BRAKE FLUID until the fluid level reaches
the UPPER mark on the reservoir.
9.
Bleed brake system. See
10. Turn ignition/light switch ON. Test operation of brake lamp
with the rear brake applied.
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)
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)
11. Test ride motorcycle at low speed. If brake feels spongy,
repeat bleeding procedure.
2-72 2009 Sportster Service: Chassis
2.14
REAR BRAKE MASTER CYLINDER: XR MODELS
GENERAL
The rear brake master cylinder is mounted to the right side
rider footrest/rear brake pedal bracket.
If the rear brake feels spongy or excessive pedal travel exists
or the brake does not work at all, proceed with Inspection which
follows.
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)
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
1.
Check the level of fluid in the rear brake reservoir. If it is
low, refill and bleed brake system. See
2.
Check for fluid leaks in the brake line, around banjo fittings
or rear brake caliper piston or bleeder valve. Repair and
bleed brake system.
a.
For brake line replacement procedure, see
.
b.
To repair rear brake caliper, see procedure in
2.17 REAR BRAKE CALIPER: XR MODELS
.
c.
See
1.8 BLEEDING HYDRAULIC BRAKE SYSTEM
for hydraulic brake system bleeding procedure.
3.
Check rear brake friction pads and disc for excessive wear
or damage. Replace worn or damaged items.
a.
See
1.10 BRAKE PADS AND DISCS: XR MODELS
for specifications.
b.
1.10 BRAKE PADS AND DISCS: XR MODELS,
for brake pad
replacement procedure.
c.
for brake disc replacement pro-
cedure.
4.
Eliminate any air in the hydraulic brake assembly by
bleeding the system. See
If none of these conditions exist but the rear brake system does
not operate properly, the rear master cylinder is most likely
defective and must be repaired or replaced.
REMOVAL
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)
1.
See
. Drain rear brake master cylinder
reservoir (7) and remove feed hose (8) from master cyl-
inder feed hose port fitting. See
. Discard hose clamp.
2.
Install end of a length of 5/16 in. (7.9 mm) I.D. clear plastic
tubing over rear caliper bleeder valve and place free end
of tubing in a suitable container.
3.
Open bleeder valve about 1/2-turn. Pump brake pedal to
drain brake fluid. Close bleeder valve but do not tighten.
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)
4.
Remove retaining ring (1) from clevis pin (2). Remove
clevis pin and disengage master cylinder yoke (3) from
brake pedal. Discard retaining ring.
NOTE
Damaged banjo bolt surfaces will leak when reassembled.
Prevent damage to seating surfaces by carefully removing
brake line components.
5.
Remove banjo bolt (6) and washers (5). Lift banjo fitting
away from master cylinder. Discard washers.
6.
Remove two screws (4) securing rear master cylinder to
master cylinder mounting bracket and remove rear master
cylinder.
7.
If it is necessary to remove master cylinder/footpeg
mounting bracket, remove fasteners (9). Refer to
2.42 RIDER FOOT CONTROLS: XR MODELS
for disas-
sembly and repair procedures.
2009 Sportster Service: Chassis 2-73
1
2
3
6
5
4
7
8
9
sm05287
1.
Retaining ring
2.
Clevis pin
3.
Yoke
4.
Screw and washer (2)
5.
Washer (2)
6.
Banjo bolt
7.
Reservoir
8.
Feed hose
9.
Fastener (2)
Figure 2-110. Rear Brake Master Cylinder and Reservoir
DISASSEMBLY
NOTE
•
Do not disassemble the rear master cylinder unless prob-
lems are being experienced. Discard all seals during the
disassembly procedure. Install a complete rebuild kit when
the unit is reassembled.
•
Clamp rear brake master cylinder in a vise by its mounting
bosses only. Use brass or aluminum jaw covers or other
protective device on vise jaws to prevent damage to
master cylinder.
1.
See
. Clamp rear brake master cylinder in a
vise with yoke (3) pointing up.
NOTE
See
. Grip yoke by the edges with an adjustable
wrench. Do not grip yoke by the flats or the yoke may become
deformed.
2.
See
. Hold yoke with an adjustable wrench.
Using an open-end wrench, loosen shoulder nut. Remove
yoke.
3.
.Remove nut (4) from push rod.
4.
Remove and discard boot (5).
NOTE
Do not remove boot collar nut (8) from push rod.
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.
5.
Thread nut (4) back onto push rod several turns, to protect
push rod threads. Press down on push rod to compress
piston spring (12). Remove retaining ring (6), push rod (7)
with boot collar nut (8), piston (10) with secondary cup (9),
primary cup (11) and piston spring (12). Discard retaining
ring, piston/cup assembly and piston spring.
6.
Remove dust cover (16), retaining ring (15), feed port fitting
(14) and o-ring (13). Discard retaining ring and o-ring.
sm05298
Figure 2-111. Holding Yoke (Top: Incorrect, Bottom:
Correct)
2-74 2009 Sportster Service: Chassis
1
4
5
11
12
17
16
15
13
14
10
10
11
9
9
19
20
2
3
6
7
8
18
sm05290
11.
1.
Primary cup*
Retaining ring
2.
12.
Clevis pin
Piston spring*
13.
3.
O-ring
Yoke
4.
14.
Nut
Feed port fitting
15.
5.
Retaining ring
Boot*
6.
16.
Retaining ring*
Dust cover
17.
7.
Master cylinder body
Push rod
8.
18.
Boot collar nut
Push rod retainer
19.
9.
G40M brake grease*
Secondary cup*
10.
20.
Piston*
CCI #20 brake grease*
Figure 2-112. Rear Brake Master Cylinder (*Provided in Service Parts Kit)
CLEANING, INSPECTION AND REPAIR
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)
1.
See
. Thoroughly clean master cylinder body
(17) and all brake system components. Blow out drilled
passages and piston bore in master cylinder body with
low pressure compressed air from a clean air supply. Do
2009 Sportster Service: Chassis 2-75
not use a wire or similar instrument to clean drilled pas-
sages.
2.
Carefully inspect all parts for wear or damage and replace
as necessary.
a.
Inspect piston bore in master cylinder housing for
scratches, grooves, scoring, pitting or corrosion.
Replace housing if any of these conditions are found.
b.
Inspect outlet port that mates with brake line banjo
fitting. This is a critical sealing surface. Replace
housing if any scratches, dents or other damage is
found.
3.
Verify that vent holes in master cylinder are completely
open and free of dirt or debris.
ASSEMBLY
NOTES
•
When assembling rear brake master cylinder, always use
new parts from the service parts kit. Consult the PARTS
CATALOG for the correct kit part number.
•
CCI #20 BRAKE GREASE is recommended for lubrication
of cylinder bore, cups and seals prior to assembly.
•
Stand master cylinder on wooden block or clean, lint-free
towel to protect seating surfaces.
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.
1.
. Coat new o-ring (13) with HARLEY-
DAVIDSON D.O.T. 4 BRAKE FLUID. Install o-ring and
feed port fitting (14) into feed port on master cylinder body
(17). Secure with new retaining ring (15). Verify that
retaining ring is fully seated in groove.
2.
Slide dust cover (16) onto feed port fitting and press into
place in master cylinder feed port.
NOTE
Clamp rear brake master cylinder body (17) in a vise by its
mounting bosses only. Use brass jaw covers or other protective
device on vise jaws to prevent damage to master cylinder.
3.
Clamp master cylinder in a vise with banjo fitting end
pointing down.
4.
See
. Lubricate master cylinder bore, new
piston (1) with new secondary cup (3), and new primary
cup (2) with CCI #20 BRAKE GREASE supplied in the
service parts kit.
Wear safety glasses or goggles when removing or
installing spring. Spring tension can cause spring,
attached components and/or hand tools to fly out which
could result in death or serious injury. (00477c)
5.
Press small end of new piston spring (4) onto mounting
boss (8) on piston.
1
2
3
4
5
6
7
8
sm05294
1.
Piston
2.
Primary cup
3.
Secondary cup
4.
Piston spring
5.
Push rod
6.
Boot collar nut
7.
Push rod retainer
8.
Piston spring mounting boss
Figure 2-113. Rear Master Cylinder Piston, Push Rod and
Spring Assembly
6.
Slide piston/spring assembly, flared end of spring first,
into cylinder bore so that spring seats against counter bore
(recess) at bottom of cylinder.
7.
Apply approximately 0.1 g of G40M BRAKE GREASE to
ball end of push rod (5).
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.
8.
See
. Temporarily thread nut (4) onto push
rod (7) several turns to protect push rod threads.
9.
Insert push rod into master cylinder body. Press down on
push rod to compress piston spring (12). Slide push rod
retainer (18) down into master cylinder bore and hold in
place.
10. Secure push rod assembly with new retaining ring (6).
Verify that retaining ring is fully seated in groove. Remove
nut (4) from push rod.
2-76 2009 Sportster Service: Chassis
11. See
. Apply approximately 0.1 g of G40M
BRAKE GREASE around groove (4) in boot collar nut (3).
Carefully slide inner boot (5) down onto push rod (2) and
into end of master cylinder bore. Press lip of inner boot
down around groove in boot collar nut.
12. See
. Thread nut (4) onto push rod (7), sev-
eral turns past flats.
13. Thread yoke (3) onto push rod, at least 2-3 turns past flats.
2
4
1
3
5
sm05295
1.
Rear brake master cylinder assembly
2.
Push rod
3.
Boot collar nut
4.
Groove
5.
Inner boot
Figure 2-114. Lubricating and Installing Inner Boot
14. See
. Measure distance (3) from centerline
of clevis pin hole (1) in yoke to centerline of master cylinder
mounting boss hole (2) closest to yoke. This distance must
be 2.64-2.76 in. (67.1-70.1 mm). Adjust yoke until this
distance is obtained.
NOTE
See
. Grip yoke by the edges with adjustable
wrench. do not grip yoke by the flats or the yoke may become
deformed.
15. See
. While holding yoke with an adjustable
wrench, turn shoulder nut back against yoke. Tighten to
130-173 in-lbs (14.7-19.6 Nm).
16. Remove master cylinder assembly from vise.
1
2
3
sm05299
1.
Clevis pin hole
2.
Mounting boss hole
3.
Adjustment distance
Figure 2-115. Adjusting Push Rod Length
INSTALLATION
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)
1.
. Assemble and install master cyl-
inder/footpeg mounting bracket if it was removed. See
2.42 RIDER FOOT CONTROLS: XR MODELS
.
2.
Install rear master cylinder assembly to mounting bracket
with screws and washers (4). Tighten to 72-96 in-lbs (8.1-
10.9 Nm).
3.
Fit yoke (3) onto foot pedal. Install clevis pin (2) and secure
with new retaining ring (1).
NOTE
Master cylinder housing has a positive stop for banjo fitting.
When tightening banjo bolt into master cylinder in the next
step, rotate banjo fitting clockwise until it contacts positive stop.
4.
Position a new washer (5) on each side of hydraulic brake
line banjo fitting. Insert banjo bolt (6) through washers and
fitting. Thread banjo bolt into master cylinder housing.
Tighten to 20-25 ft-lbs (27.1-33.9 Nm).
5.
Install rear brake master cylinder feed hose (8) on master
cylinder feed hose port fitting. Secure with new hose
clamp.
2009 Sportster Service: Chassis 2-77
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)
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)
NOTES
•
If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.
•
Rear brake master cylinder reservoir must be in a level
position when filling and checking fluid level.
•
Reservoir cover may be removed from rear brake master
cylinder reservoir to more easily verify fluid level in reser-
voir.
•
Use only HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID
from a sealed container.
•
Do not overfill reservoir. Do not reuse old brake fluid.
6.
Position motorcycle upright (not resting on jiffy stand).
7.
. Remove reservoir cap (2).
8.
Fill rear master cylinder reservoir (1) with HARLEY-DAV-
IDSON D.O.T. 4 BRAKE FLUID until the fluid level reaches
the UPPER mark (3) on the reservoir.
9.
Bleed brake system. See
10. Turn ignition/light switch ON. Test operation of brake lamp
with the rear brake applied.
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)
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)
11. Test ride motorcycle at low speed. If brake feels spongy,
repeat bleeding procedure.
2
1
3
4
sm05262
1.
Rear brake master cylinder reservoir
2.
Reservoir cap
3.
Upper fluid level
4.
Lower fluid level
Figure 2-116. Rear Brake Master Cylinder Reservoir (XR
Models)
2-78 2009 Sportster Service: Chassis
2.15
REAR BRAKE MASTER CYLINDER RESERVOIR
GENERAL
The rear brake master cylinder is equipped with a remote fluid
reservoir. On XL models, this reservoir is located to the rear
of the primary cover, below the left side cover. On XR models,
the reservoir is mounted on the right side rider footrest/rear
brake pedal bracket.
REMOVAL: XL MODELS
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)
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.
1.
Position motorcycle upright on suitable lift.
2.
See
. Grasp reservoir cover (2) and gently
pull straight out from reservoir (1).
3.
Remove screw with captive washer (3).
4.
Remove reservoir cap (4). Hold reservoir upside down
over a suitable container and drain brake fluid.
5.
Loosen hose clamp (5) and pull feed hose (6) from reser-
voir. Slide hose clamp off free end of feed hose.
6.
. Slide feed hose (2) down through B-
clamp (3). Hold free end of hose down over container and
drain any brake fluid remaining in hose.
7.
Loosen hose clamp (4) and pull feed hose off feed hose
port (5) on master cylinder (1).
8.
Cover feed hose port with a clean, lint-free cloth to keep
dirt and debris out of master cylinder.
2
1
5
6
4
3
sm01331
1.
Rear brake master cylinder reservoir
2.
Reservoir cover
3.
Mounting screw with captive washer
4.
Reservoir cap
5.
Hose clamp
6.
Master cylinder feed hose
Figure 2-117. Reservoir Mount
2009 Sportster Service: Chassis 2-79
3
2
1
4
5
sm01332
1.
Rear brake master cylinder
2.
Master cylinder feed hose
3.
B-clamp
4.
Hose clamp
5.
Feed hose port
Figure 2-118. Master Cylinder Feed Hose
INSTALLATION: XL MODELS
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)
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.
1.
See
. Slide end of feed hose (2) onto feed
hose port (5) on master cylinder (1). Secure feed hose to
fitting with hose clamp (4).
2.
Slide free end of feed hose up through B-clamp (3).
3.
See
. Slide hose clamp (5) onto free end of
feed hose (6).
4.
Push feed hose onto fitting on reservoir (1) and secure
with hose clamp.
5.
Install reservoir using screw with captive washer (3).
Tighten to 20-25 in-lbs (2.3-2.8 Nm).
NOTES
•
Rear brake master cylinder reservoir must be in a level
position when filling and checking fluid level.
•
Use only HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID
from a sealed container.
•
Do not overfill reservoir. Do not reuse old brake fluid.
6.
Position motorcycle upright (not resting on jiffy stand). Fill
master cylinder reservoir with HARLEY-DAVIDSON D.O.T.
4 BRAKE FLUID until the fluid level reaches the UPPER
mark on the reservoir.
7.
Bleed brake system. See
8.
Install reservoir cover (2).
9.
Turn ignition/light switch ON. Test operation of brake lamp
with the rear brake applied.
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)
10. Test ride motorcycle. If brake feels spongy, repeat bleeding
procedure.
REMOVAL: XR MODELS
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)
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.
1.
Position motorcycle upright on suitable lift.
2.
See
. Loosen reservoir cap (2).
3.
Remove screw (6).
4.
Remove reservoir cap (2). Hold reservoir upside down
over a suitable container and drain brake fluid.
5.
Loosen hose clamp (3) and pull feed hose (4) from reser-
voir. Slide hose clamp off free end of feed hose.
2-80 2009 Sportster Service: Chassis
6.
Loosen hose clamp (5) and pull feed hose off master cyl-
inder. Cover feed hose port with a clean, lint-free cloth to
keep dirt and debris out of master cylinder.
2
1
3
4
6
5
sm05303
1.
Rear brake master cylinder reservoir
2.
Reservoir cap
3.
Hose clamp
4.
Feed hose
5.
Hose clamp (master cylinder)
6.
Screw
Figure 2-119. Rear Brake Master Cylinder Reservoir: XR
Models
INSTALLATION: XR MODELS
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)
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.
1.
See
. Slide end of feed hose (4) onto feed
hose port on master cylinder. Secure feed hose to fitting
with hose clamp (5).
2.
Slide hose clamp (3) onto free end of feed hose (4).
3.
Push feed hose onto fitting on reservoir (1) and secure
with hose clamp.
4.
Install reservoir using screw (6). Tighten to 36-60 in-lbs
(4.1-6.8 Nm).
NOTES
•
Rear brake master cylinder reservoir must be in a level
position when filling and checking fluid level.
•
Use only HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID
from a sealed container.
•
Do not overfill reservoir. Do not reuse old brake fluid.
5.
Position motorcycle upright (not resting on jiffy stand). Fill
master cylinder reservoir with HARLEY-DAVIDSON D.O.T.
4 BRAKE FLUID until the fluid level reaches the UPPER
mark on the reservoir.
6.
Bleed brake system. See
7.
Install reservoir cover (2).
8.
Turn ignition/light switch ON. Test operation of brake lamp
with the rear brake applied.
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)
9.
Test ride motorcycle. If brake feels spongy, repeat bleeding
procedure.
2009 Sportster Service: Chassis 2-81
2.16
REAR BRAKE CALIPER: XL MODELS
REMOVAL
NOTE
If only replacing brake pads, do not remove rear brake caliper.
For brake pad replacement only, see
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)
NOTE
Damaged banjo bolt surfaces will leak when reassembled.
Prevent damage to seating surfaces by carefully removing
brake line components.
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)
NOTES
•
Do not remove rear caliper from mounting bracket unless
caliper mounting pins and boots require service. Removing
caliper from mounting bracket unnecessarily increases
the risk of contaminants falling into caliper boots and
bushings which could damage 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 D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY 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.
3.
. Remove the banjo bolt (1) and both
washers (2) to detach rear brake line (3) from brake caliper
(4). Discard washers.
4.
Remove pad pin plug (6).
5.
See
. Remove brake pad pin.
6.
See
. Remove brake pads (15).
7.
Remove rear wheel. See
8.
. Remove rear brake caliper (4) and
caliper mounting bracket (5) as an assembly.
2
3
5
1
4
8
6
7
sm03595
1.
Banjo bolt
2.
Washer (2)
3.
Rear brake line
4.
Brake caliper
5.
Caliper mounting bracket
6.
Pad pin plug
7.
Bleeder valve
8.
Damper
Figure 2-120. Rear Caliper Assembly
sm01451
Figure 2-121. Brake Pad Pin (Plug Removed)
2-82 2009 Sportster Service: Chassis
15
1
3
5
4
20
18
17
6
7
8
9
10
11
12
16
19
2
13
14
sm01813
11.
1.
Bleeder nipple cap
Caliper mounting bracket
2.
12.
Pad spring
Bleeder valve
13.
3.
Brake pad (2)
Caliper pin boot
4.
14.
Damper
Pad retainer (2)
15.
5.
Brake pad set (includes item 20)
Mounting bracket bolt pin (do not remove)
6.
16.
Caliper body
Piston
17.
7.
Piston seal
Caliper bolt pin (do not remove)
8.
18.
Caliper bushing boot
Dust seal
19.
9.
Piston kit
Pad pin plug
10.
20.
Pad pin
Retainer clip (not sold separately)
Figure 2-122. Rear Brake Caliper Assembly
2009 Sportster Service: Chassis 2-83
DISASSEMBLY
1.
See
. Remove pad spring (2). Do not remove
bleeder valve (12) at this time.
2.
. 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.
3.
Loosely install brake pad pin (2) to hold brake pad in place.
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)
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
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.
4.
See
. Gently apply low pressure compressed
air to banjo bolt hole (3) to force piston from caliper bore.
5.
Remove brake pad pin and brake pad from caliper.
6.
See
. 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.
. Using a wooden toothpick (1), remove
dust seal (2) and piston seal (3) from caliper bore. Discard
seals.
8.
. If necessary, remove bleeder valve
(12).
3
4
1
2
5
sm01453
1.
Brake caliper
2.
Brake pad pin
3.
Brake pad friction material
4.
Brake pad backing plate
5.
Brake caliper mounting bracket
Figure 2-123. Preparing Caliper for Piston Removal
4
2
3
1
sm01454
1.
Low pressure air nozzle
2.
Brake caliper
3.
Banjo bolt hole
4.
Brake pad
Figure 2-124. Removing Piston (Caliper Removed from
Mounting Bracket for Clarity)
2-84 2009 Sportster Service: Chassis
1
2
3
sm01455
1.
Wooden toothpick
2.
Dust seal
3.
Piston seal
Figure 2-125. Caliper Seals
CLEANING, INSPECTION AND REPAIR
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)
1.
Clean piston bore with denatured alcohol.
2.
Clean all rubber parts with HARLEY-DAVIDSON D.O.T.
4 BRAKE FLUID. Do not contaminate with mineral oil or
other solvents. Wipe parts dry with a clean, lint free cloth.
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)
3.
Blow out drilled passages and piston bore with low pres-
sure 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 piston (16) for pitting, scratching or corrosion
on outside surfaces.
b.
Inspect caliper (6) piston bore. Do not hone bore. If
bore shows pitting or corrosion, replace caliper.
c.
Inspect pad pin (10) 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.
Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)
5.
Inspect brake pads (13) and brake disc. Replace if
necessary.
a.
See
1.9 BRAKE PADS AND DISCS: XL MODELS
for
specifications.
b.
See
for brake disc replacement pro-
cedure.
LUBRICATING REAR CALIPER BOLT PINS
AND BOOTS
1.
See
. Apply approximately 0.4 g of G40M
BRAKE GREASE inside caliper bushing boot (3) and cal-
iper pin boot (4).
2.
. Apply G40M BRAKE GREASE inside
boot lip (8) to prevent sticking between boots (3, 4) and
bolt pins (5, 6).
3.
Insert mounting bracket bolt pin (6) into caliper bushing
boot (3).
3
2
6
4
5
1
sm01458
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)
Figure 2-126. Lubricating Caliper Boots and Pins
2009 Sportster Service: Chassis 2-85
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст