Harley Davidson Sportster Models 2009. Service Repair Manual — page 2

Lubricate the following parts prior to assembly using a
light coat of KS62F assembly grease from the service
parts kit. All other surfaces must be dry for assembly.

Nose radius of piston.

All surfaces of piston seal and dust seal.

NOTE

A damaged piston bore will leak when reassembled. Do not
use metal objects to remove or install components in piston
bore. Prevent damage to bore by only using a wooden toothpick
when servicing caliper.

See

Figure 2-141

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

dust seal (2) into piston bore.

Carefully insert piston by hand, nose radius first, into cal-
iper bore. If installation shows resistance, remove piston
and check that seals are properly installed and fully seated
in grooves.

Install bleeder valve if removed. Do not tighten bleeder
valve at this time.

sm05122

Pad spring

Bushing

Boot

Figure 2-140. Assemble Caliper

sm05115

Wooden toothpick

Dust seal

Piston seal

Figure 2-141. Caliper Seals

INSTALLATION

See

Figure 2-142

. If removed, install bolt pin boot (1).

Apply approximately 0.4 g of G40M BRAKE GREASE
inside bolt pin boot.

If removed, install wear plate (2) on mounting bracket.

See

Figure 2-143

. Apply a drop of LOCTITE 272 Thread

Lock to threads of bolt pin (6).

Place rear caliper assembly onto mounting bracket. Install
bolt pin (6), being careful not to pinch or roll boot over.
Tighten bolt pin to 14-18 ft-lbs (19.6-24.5 Nm). See

Figure 2-144

. Ensure lip of boot (1) properly engages the

groove (2) in the bolt pin.

See

Figure 2-143

. Install mounting bolt (5) and tighten to

14-18 ft-lbs (19.6-24.5 Nm).

NOTE

Brake caliper housing has a positive stop for banjo fitting. When
tightening banjo bolt into brake caliper in the next step, rotate
banjo fitting clockwise until it contacts positive stop.

Position a new washer (3) on each side of hydraulic brake
line (1) banjo fitting. Insert banjo bolt (2) through washers
and fitting and thread bolt into caliper housing. Tighten to
20-25 ft-lbs (27.1-33.9 Nm).

Install brake pads. See

1.10 BRAKE PADS AND DISCS:

XR MODELS, Brake Pad Replacement: Rear

Secure lower end of shock absorber to rear fork. Tighten
to 30-45 ft-lbs (40.7-61.0 Nm)

10. Adjust drive belt and check vehicle alignment. See

1.16 REAR BELT DEFLECTION

HOME

2-94 2009 Sportster Service: Chassis

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.

11. Remove rear brake master cylinder reservoir cap. Add

HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID to reservoir
until fluid reaches upper fluid level (3). Do not overfill
reservoir. Do not reuse brake fluid.

12. Bleed brake system. See

1.8 BLEEDING HYDRAULIC

BRAKE SYSTEM

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)

13. Verify proper operation of master cylinder relief port.

Press against rear brake caliper to push caliper piston
back into its bore. This pushes brake fluid back
through master cylinder and verifies that relief port is
not plugged.

Pump brake pedal until caliper piston pushes pads
against disc and pressure is returned to brake system.

14. Add HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID to

reservoir until fluid reaches upper fluid level.

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)

15. Test brake system.

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

Test ride motorcycle at low speed. If brakes feel
spongy, bleed system again. See

1.8 BLEEDING

HYDRAULIC BRAKE SYSTEM

NOTE

Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.

sm05120

Bolt pin boot

Wear plate

Figure 2-142. Caliper Mount

sm05109

Rear brake line

Banjo bolt

Washer (2)

Bleeder valve

Mounting bolt

Bolt pin

Figure 2-143. Rear Caliper Assembly

HOME

2009 Sportster Service: Chassis 2-95

sm05123

Boot

Bolt pin groove

Figure 2-144. Bolt Pin and Boot

HOME

2-96 2009 Sportster Service: Chassis

Была ли эта страница вам полезна?

Да!Нет

5 посетителей считают эту страницу полезной.

Harley Davidson Sportster Models 2009. Service Repair Manual — page 2

Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.