Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 10
HOME
NOTE
REMOVAL
Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.
1WARNING
4. Remove retaining ring (11) from clevis pin (9). Remove
clevis pin and disengage master cylinder yoke (10) from
Direct contact of D.O.T. 5 brake fluid with eyes can cause
bell crank (12). Discard retaining ring.
eye irritation, swelling, and redness. Avoid eye contact.
In case of eye contact flush with large amounts of water
CAUTION
and get medical attention. Swallowing large amounts of
D.O.T. 5 brake fluid can cause digestive discomfort. If
Damaged banjo bolt surfaces will leak when reassembled.
swallowed, obtain medical attention. Use in well venti-
Prevent damage to seating surfaces by carefully removing
lated area. KEEP OUT OF REACH OF CHILDREN.
brake line components.
(00144a)
5. Remove banjo bolt (18) and washers (16) from master
1.
See Figure 2-84. Drain rear brake master cylinder reser-
cylinder (6). Lift banjo fitting away from master cylinder.
voir (1) and remove hose clamp (4) and feed hose (3)
Discard washers.
from master cylinder feed hose port fitting (5). See 2.13
6. Remove two screws (7) and two washers (8) securing
REAR BRAKE MASTER CYLINDER RESERVOIR. Dis-
rear master cylinder to master cylinder mounting bracket
card hose clamp.
(15) and remove rear master cylinder.
2.
Remove bleeder nipple cap (21) from bleeder valve (22)
7. If it is necessary to remove master cylinder mounting
on rear brake caliper (20). Install end of a length of 5/16
bracket:
in. (7.9 mm) I.D. clear plastic tubing over caliper bleeder
valve, while placing free end in a suitable container.
a. Remove retaining ring (14) and clevis pin (13). Dis-
connect bell crank (12) from mounting bracket.
3.
Open bleeder valve about 1/2-turn. Pump brake pedal to
drain brake fluid. Close bleeder valve but do not tighten.
b. Remove two screws (23).
c. Remove screw (24) and mounting bracket.
1WARNING
Wear safety glasses or goggles when removing or install-
ing retaining rings. Retaining rings can slip from the pli-
ers and could be propelled with enough force to cause
serious eye injury. (00312a)
2-50
2006 Sportster: Chassis
HOME
x0573a2x
21
22
19
18
1
2
20
3
4
5
17
23
16
6
13
7
8
15
9
10
11
12
14
24
1.
Rear brake master cylinder reservoir
13. Clevis pin
2.
B-clamp
14. Retaining ring
3.
Master cylinder feed hose
15. Master cylinder mounting bracket
4.
Hose clamp
16. Washer (2)
5.
Feed hose port fitting
17. Banjo fitting
6.
Rear brake master cylinder
18. Banjo bolt
7.
Screw (2)
19. Rear brake line including stoplight switch
8.
Washer (2)
20. Rear brake caliper
9.
Clevis pin
21. Bleeder nipple cap
10. Yoke
22. Bleeder valve
11. Retaining ring
23. Screw (2)
12. Bell crank
24. Screw
Figure 2-84. Rear Brake Master Cylinder and Reservoir
2006 Sportster: Chassis
2-51
HOME
DISASSEMBLY
1
WARNING
NOTE
Wear safety glasses or goggles when removing or install-
Do not disassemble the rear master cylinder unless problems
ing retaining rings. Retaining rings can slip from the pli-
are being experienced. Discard all seals during the disas-
ers and could be propelled with enough force to cause
sembly procedure. Install a complete rebuild kit when the unit
serious eye injury. (00312a)
is reassembled.
NOTE
Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.
CAUTION
6. Thread shoulder nut back onto push rod several turns, to
See Figure 2-86. Clamp rear brake master cylinder (19) in
protect push rod threads. Press down on push rod to
a vise by its mounting bosses (18) only. Use brass or alu-
compress piston spring (17). Remove retaining ring (10),
minum jaw covers or other protective device on vise jaws
push rod with boot collar nut (9) and push rod retainer
to prevent damage to master cylinder.
(11), piston (15) with secondary cup (14), primary cup
1.
See Figure 2-86. Clamp rear brake master cylinder (19)
(16) and piston spring. Discard retaining ring, piston with
in a vise with yoke (3) pointing up.
secondary cup, primary cup and piston spring.
2.
Remove external boot (5). Remove spring pin (12) from
7. Remove dust cover (23), retaining ring (22), feed port fit-
end of push rod (13). Discard spring pin.
ting (21) and O-ring (20). Discard retaining ring and O-
ring.
CAUTION
See Figure 2-85. Grip yoke by the edges with an adjust-
10431
able wrench. Do not grip yoke by the flats or the yoke
may become deformed and damaged.
3.
See Figure 2-85. Hold yoke with an adjustable wrench.
Using an open-end wrench, loosen shoulder nut.
Unscrew and remove yoke.
INCORRECT
1WARNING
Always wear eye protection when disassembling master
cylinder. Spring pressure could propel components with
enough force to cause death or serious injury.
4.
See Figure 2-86. Press down on spring retainer (6) to
compress external return spring (7). While spring is com-
pressed, unscrew shoulder nut from push rod. Carefully
release pressure on external return spring. Remove
spring retainer and external return spring.
CORRECT
5.
Remove and discard inner boot (8).
NOTE
Do not remove boot collar nut (9) and push rod retainer (11)
from push rod.
10432
Figure 2-85. Tightening Yoke
2-52
2006 Sportster: Chassis
HOME
x0577x2x
15
23
14
22
19
21
20
12
18
10
17
16
13
2
3
8
7
6
4
5
1
11
9
Provided in Service Parts Kit
1.
Retaining ring
13.
Push rod
2.
Clevis pin
14.
Secondary cup
3.
Yoke
15.
Piston
4.
Shoulder nut
16.
Primary cup
5.
External boot
17.
Piston spring
6.
Spring retainer
18.
Mounting boss (2)
7.
External return spring
19.
Master cylinder body
8.
Inner boot
20.
O-ring
9.
Boot collar nut
21.
Feed port fitting
10.
Retaining ring
22.
Retaining ring
11.
Push rod retainer
23.
Dust cover
12.
Spring pin
Figure 2-86. Rear Brake Master Cylinder
2006 Sportster: Chassis
2-53
HOME
CLEANING, INSPECTION AND
ASSEMBLY
REPAIR
NOTES
● When assembling rear brake master cylinder, always use
1WARNING
new parts from the service parts kit. Consult your parts
catalog for the correct kit part number.
Always use denatured alcohol to clean metal brake sys-
● HARLEY-DAVIDSON D.O.T. 5 BRAKE FLUID is recom-
tem components and HARLEY-DAVIDSON D.O.T.
5
mended for lubrication of cylinder bore, cups and seals
BRAKE FLUID to clean rubber brake system compo-
prior to assembly.
nents. Do not use mineral-base cleaning solvents, such
as gasoline or paint thinner. Use of mineral-base sol-
● Stand master cylinder on wooden block or clean, lint-free
vents causes deterioration of rubber parts that continues
towel to protect seating surfaces.
after assembly. This may result in improper brake opera-
tion which could result in death or serious injury.
1
WARNING
1WARNING
Wear safety glasses or goggles when removing or install-
ing retaining rings. Retaining rings can slip from the pli-
Compressed air can pierce the skin and flying debris from
ers and could be propelled with enough force to cause
compressed air could cause serious eye injury. Wear
serious eye injury. (00312a)
safety glasses when working with compressed air. Never
NOTE
use your hand to check for air leaks or to determine air
Use correct retaining ring pliers and correct tips. Verify that
flow rates. (00061a)
tips are not excessively worn or damaged.
1.
See Figure 2-86. Thoroughly clean master cylinder body
1. See Figure 2-86. Coat new O-ring (20) with HARLEY-
(19) and all brake system components. Blow out drilled
DAVIDSON D.O.T. 5 BRAKE FLUID. Install O-ring and
passages and piston bore in master cylinder body with
feed port fitting (21) into feed port on top of master cylin-
low pressure compressed air from a clean air supply. Do
der (19). Secure with new retaining ring (22). Verify that
not use a wire or similar instrument to clean drilled pas-
retaining ring is fully seated in groove.
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.
2-54
2006 Sportster: Chassis
HOME
2.
Slide dust cover (23) onto feed port fitting and press into
10443
place in master cylinder feed port. See Figure 2-87. Turn
7
feed port fitting (4) so it points toward banjo fitting (5) end
6
1
of master cylinder body (1).
x0579x2x
4
5
5
3
4
2
1.
Piston
2
2.
Primary cup
3.
Secondary cup
4.
Piston spring
5.
Push rod
6.
Boot collar nut
1
7.
Push rod retainer
3
Figure 2-88. Rear Master Cylinder Piston,
Push Rod and Spring Assembly
1.
Rear master cylinder assembly
2.
External boot
6. Insert piston (1) with secondary cup (3) into cylinder bore
3.
Ears (2)
with flat end of piston facing primary cup.
4.
Feed port fitting
7. Apply approximately 0.1 g of G40M BRAKE GREASE to
5.
Banjo fitting hole
ball end of push rod (5). Insert ball end of push rod into
Figure 2-87. Assembled Rear Master Cylinder
cupped end of piston.
1WARNING
CAUTION
Wear safety glasses or goggles when removing or install-
See Figure 2-86. Clamp rear brake master cylinder (19) in
ing retaining rings. Retaining rings can slip from the pli-
a vise by its mounting bosses (18) only. Use brass jaw
ers and could be propelled with enough force to cause
covers or other protective device on vise jaws to prevent
serious eye injury. (00312a)
damage to master cylinder.
NOTE
3.
Clamp master cylinder in a vise with banjo fitting end
Use correct retaining ring pliers and correct tips. Verify that
pointing down.
tips are not excessively worn or damaged.
4.
Lubricate master cylinder bore, new piston (15) with sec-
8. See Figure 2-86. Temporarily thread shoulder nut (4)
ondary cup (14), and new primary cup (16) with HAR-
onto push rod (13) several turns to protect push rod
LEY-DAVIDSON D.O.T. 5 BRAKE FLUID.
threads. Press down on push rod to compress piston
spring (17). Slide push rod retainer (11) down into mas-
1WARNING
ter cylinder bore.
9. Secure push rod assembly with new retaining ring (10).
Always wear eye protection when assembling master cyl-
Verify that retaining ring is fully seated in groove.
inder. Spring pressure could propel components with
Unthread shoulder nut from push rod.
enough force to cause death or serious injury.
5.
See Figure 2-88. Install new primary cup (2) onto small
end of new piston spring (4) with open end of cup facing
spring. Slide piston spring with primary cup into master
cylinder bore with large end of spring facing down.
2006 Sportster: Chassis
2-55
HOME
10. See Figure 2-89. Apply approximately 0.1 g of G40M
BRAKE GREASE around groove (4) in boot collar nut
CAUTION
(3). Carefully slide inner boot (5) down onto push rod (2)
and into end of master cylinder bore. Press lip of inner
See Figure 2-85. Grip yoke by the edges with adjustable
wrench. Do not grip yoke by the flats or the yoke may
boot down around groove in boot collar nut.
become deformed and damaged.
11. See Figure 2-86. Install external return spring (7) and
spring retainer (6). Thread shoulder nut (4) shoulder-first
14. See Figure
2-85. Holding yoke with an adjustable
onto push rod (13), several turns past flats.
wrench, turn shoulder nut back against yoke. Tighten to
130-173 in-lbs (14.7-19.6 Nm).
12. Thread yoke (3) onto push rod, at least 2-3 turns past
flats. Install new spring pin (12) into end of push rod.
15. Remove master cylinder assembly from vise. See Figure
2-87. Slide external boot (2) over yoke/push rod assem-
bly and external return spring.
x0580x2x
16. Position external boot so that “ears” (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 bot-
tom of boot when master cylinder is mounted on motor-
cycle. Make sure that lip on large end of external boot fits
4
fully in groove in end of master cylinder. Make sure that
spring retainer is fully seated in groove in small end of
external boot.
2
10442
1
3
5
1.
Rear brake master cylinder assembly
2.
Push rod
3.
Boot collar nut
3.40-3.48 in.
4.
Groove
(86.3-88.3 mm)
5.
Inner boot
Figure 2-89. Lubricating and Installing Inner Boot
13. See Figure 2-90. Measure distance from centerline of
clevis pin hole in yoke to centerline of master cylinder
mounting boss 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.
Figure 2-90. Adjusting Push Rod Length
2-56
2006 Sportster: Chassis
HOME
INSTALLATION
1
WARNING
Direct contact of D.O.T. 5 brake fluid with eyes can cause
1WARNING
eye irritation, swelling, and redness. Avoid eye contact.
In case of eye contact flush with large amounts of water
Wear safety glasses or goggles when removing or install-
and get medical attention. Swallowing large amounts of
ing retaining rings. Retaining rings can slip from the pli-
D.O.T. 5 brake fluid can cause digestive discomfort. If
ers and could be propelled with enough force to cause
swallowed, obtain medical attention. Use in well venti-
serious eye injury. (00312a)
lated area. KEEP OUT OF REACH OF CHILDREN.
NOTE
(00144a)
Use correct retaining ring pliers and correct tips. Verify that
NOTES
tips are not excessively worn or damaged.
●
Rear brake master cylinder reservoir must be in a level
1.
See Figure 2-84. If master cylinder mounting bracket
position when filling and checking fluid level.
(15) was removed:
●
Reservoir cover may be removed from rear brake master
a. Attach mounting bracket to frame loosely with
cylinder reservoir to more easily verify fluid level in reser-
screws (23, 24). Then tighten two screws (23) to 17-
voir.
22 ft-lbs (23.1-29.9 Nm). Tighten screw (24) to 17-
22 ft-lbs (23.1-29.9 Nm)
● Use only HARLEY-DAVIDSON D.O.T. 5 BRAKE FLUID
from a sealed container.
b. Install bell crank (12) with clevis pin (13). Secure
with new retaining ring (14).
● Do not overfill reservoir. Do not reuse old brake fluid.
2.
Install rear master cylinder assembly (6) on mounting
6. Position motorcycle upright (not resting on jiffy stand).
bracket (15) with screws (7) and washers (8). Tighten to
Fill rear master cylinder reservoir with HARLEY-DAVID-
15-20 ft-lbs (20.4-27.1 Nm).
SON D.O.T. 5 BRAKE FLUID until the fluid level reaches
3.
Fit yoke (10) onto bell crank (12). Install clevis pin (9) and
the UPPER mark on the reservoir.
secure with new retaining ring (11).
7. Bleed brake system. See BLEEDING REAR BRAKE
NOTE
under 1.9 BLEEDING HYDRAULIC BRAKE SYSTEM.
Master cylinder housing has a positive stop for banjo fitting.
8. Turn ignition/light switch ON. Test operation of brake
When tightening banjo bolt into master cylinder in the next
lamp with the rear brake applied.
step, rotate banjo fitting clockwise until it contacts positive
stop.
1WARNING
4.
Position a new washer (16) on each side of hydraulic
After repairing the brake system, test brakes at low
brake line banjo fitting (17). Insert banjo bolt (18) through
speed. If brakes are not operating properly, testing at
washers and fitting. Thread bolt into master cylinder
high speeds can cause loss of control, which could
housing. Tighten to 20-25 ft-lbs (27.1-33.9 Nm).
result in death or serious injury. (00289a)
5.
Install rear brake master cylinder feed hose (3) on mas-
9. Test ride motorcycle at low speed. If brake feels spongy,
ter cylinder feed hose port fitting (5). Secure with new
repeat bleeding procedure.
hose clamp (4). See 2.13 REAR BRAKE MASTER CYL-
INDER RESERVOIR.
1WARNING
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)
2006 Sportster: Chassis
2-57
HOME
REAR BRAKE MASTER CYLINDER RESERVOIR
2.13
GENERAL
10335
The rear brake master cylinder is equipped with a remote
fluid reservoir, located to the rear of the primary cover, behind
the left side cover.
REMOVAL
2
1WARNING
Direct contact of D.O.T. 5 brake fluid with eyes can cause
10333
eye irritation, swelling, and redness. Avoid eye contact.
In case of eye contact flush with large amounts of water
and get medical attention. Swallowing large amounts of
1
D.O.T. 5 brake fluid can cause digestive discomfort. If
swallowed, obtain medical attention. Use in well venti-
4
lated area. KEEP OUT OF REACH OF CHILDREN.
(00144a)
1.
Position motorcycle upright on suitable lift.
5
2.
See Figure 2-91. Grasp reservoir cover (2) and gently
pull straight out from reservoir (1).
3.
Remove screw with captive washer (3).
3
4.
Unscrew reservoir cap (4). Hold reservoir upside down
6
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.
1.
Rear brake master cylinder reservoir
6.
See Figure 2-92. Slide feed hose (2) down through B-
2.
Reservoir cover
clamp (3). Hold free end of hose down over container
3.
Mounting screw with captive washer
and drain any brake fluid remaining in hose.
4.
Reservoir cap
7.
Loosen hose clamp (4) and pull feed hose off feed hose
5.
Hose clamp
port (5) on master cylinder (1).
6.
Master cylinder feed hose
8.
Cover feed hose port with a clean, lint-free cloth to keep
dirt and debris out of master cylinder.
Figure 2-91. Reservoir Mount
10120
4
3
5
2
1
1. Rear brake master cylinder
2. Master cylinder feed hose
3. B-clamp
4. Hose clamp
5. Feed hose port
Figure 2-92. Master Cylinder Feed Hose
2-58
2006 Sportster: Chassis
HOME
7. Position motorcycle upright (not resting on jiffy stand).
INSTALLATION
Fill master cylinder reservoir with HARLEY-DAVIDSON
D.O.T. 5 BRAKE FLUID until the fluid level reaches the
UPPER mark on the reservoir.
1WARNING
8. Bleed brake system. See 1.9 BLEEDING HYDRAULIC
Direct contact of D.O.T. 5 brake fluid with eyes can cause
BRAKE SYSTEM.
eye irritation, swelling, and redness. Avoid eye contact.
9. Turn ignition/light switch ON. Test operation of brake
In case of eye contact flush with large amounts of water
lamp with the rear brake applied.
and get medical attention. Swallowing large amounts of
D.O.T. 5 brake fluid can cause digestive discomfort. If
1WARNING
swallowed, obtain medical attention. Use in well venti-
lated area. KEEP OUT OF REACH OF CHILDREN.
After repairing the brake system, test brakes at low
(00144a)
speed. If brakes are not operating properly, testing at
1.
See Figure 2-92. Slide end of feed hose (2) onto feed
high speeds can cause loss of control, which could
hose port (5) on master cylinder (1). Secure feed hose to
result in death or serious injury. (00289a)
fitting with hose clamp (4).
10. Test ride motorcycle. If brake feels spongy, repeat bleed-
2.
Slide free end of feed hose up through B-clamp (3).
ing procedure.
3.
See Figure 2-91. 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).
6.
Install reservoir cover (2).
NOTES
● Rear brake master cylinder reservoir must be in a level
position when filling and checking fluid level.
● See Figure 2-91. Reservoir cover (2) may be removed
from rear brake master cylinder reservoir (1) to more
easily verify fluid level in reservoir.
● Use only HARLEY-DAVIDSON D.O.T. 5 BRAKE FLUID
from a sealed container.
● Do not overfill reservoir. Do not reuse old brake fluid.
2006 Sportster: Chassis
2-59
HOME
FRONT BRAKE CALIPER
2.14
REMOVAL
10340
8
6
9
NOTE
If only replacing brake pads, do not remove front brake cali-
per(s). For brake pad replacement only, see 1.10 BRAKE
2
PADS AND DISCS.
1WARNING
3
Direct contact of D.O.T. 5 brake fluid with eyes can cause
eye irritation, swelling, and redness. Avoid eye contact.
5
In case of eye contact flush with large amounts of water
1
and get medical attention. Swallowing large amounts of
D.O.T. 5 brake fluid can cause digestive discomfort. If
4
swallowed, obtain medical attention. Use in well venti-
lated area. KEEP OUT OF REACH OF CHILDREN.
7
(00144a)
1.
Banjo bolt
2.
Washer (2)
CAUTION
3.
Front brake line
4.
Brake caliper
Damaged banjo bolt surfaces will leak when reassembled.
5.
Caliper mounting bracket
Prevent damage to seating surfaces by carefully removing
6.
Mounting bolt (2) (12 pt/10 mm)
brake line components.
7.
Pad pin plug
1.
See Figure 2-93. Remove bleeder nipple cap (9) from
8.
Bleeder valve
bleeder valve (8) on front brake caliper (4).
9.
Bleeder nipple cap
2.
See Figure 2-94. Install end of a length of 5/16 in. (7.9
Figure 2-93. Front Caliper Assembly
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
x0419a2x
repeatedly to drain brake fluid. Close bleeder valve.
3.
See Figure 2-93. Remove the banjo bolt (1) and both
washers (2) to detach front brake line (3) from caliper (4).
Discard washers.
4.
Remove pad pin plug (7).
5.
See Figure 2-95. Loosen, but do not remove, brake pad
pin.
6.
See Figure 2-93. Remove both mounting bolts (6) (12 pt/
10 mm). Pull caliper and mounting bracket assembly
rearward to disengage from brake disc.
Figure 2-94. Bleeding Hydraulic System
10341
Figure 2-95. Brake Pad Pin (Plug Removed)
2-60
2006 Sportster: Chassis
HOME
x0406c2x
13
16
12
14
15
11
10
20
18
19
17
7
6
21
5
4
9
3
2
8
1
1.
Caliper bracket
12.
Caliper bushing boot
2.
Caliper pin boot
13.
Pad pin plug
3.
Screw (2)
14.
Pad pin
4.
Bolt pin (caliper)
15.
Caliper body
5.
Pad retainer (2)
16.
Pad spring
6.
Insulator (2)
17.
Piston (2)
7.
Brake pad (2)
18.
Piston seal (2)
8.
Brake pad set
19.
Dust seal (2)
9.
Pad spring
20.
Piston kit
10.
Bleeder valve
21.
Bolt pin (mounting bracket)
11.
Bleeder nipple cap
Figure 2-96. Front Brake Caliper Assembly
DISASSEMBLY
1
WARNING
1.
See Figure 2-96. Remove brake pad pin (14) and brake
Compressed air can pierce the skin and flying debris
pads (8) from caliper body (15).
from compressed air could cause serious eye injury.
2.
Slide brake caliper off mounting bracket (1).
Wear safety glasses when working with compressed air.
3.
Remove pad spring (16). Do not remove bleeder valve
Never use your hand to check for air leaks or to deter-
(10) at this time.
mine air flow rates. (00061a)
4.
See Figure 2-97. Install a discarded brake pad in the cal-
iper
(1) with the backing plate (4) facing the pistons.
CAUTION
Position the brake pad so the friction material (3) is
Be careful not to damage banjo bolt sealing surface or
against the back of the caliper, as shown.
threads of banjo bolt hole in brake caliper. It is recom-
5.
Loosely install brake pad pin (2) to hold brake pad in
mended that you use an air nozzle with a rubber tip to
place.
perform the next step in this procedure.
2006 Sportster: Chassis
2-61
HOME
8986
1CAUTION
3
In the next step, the pistons will be forced out of their
1
bores and up against the brake pad backing plate. Keep
fingers away from this area. Failure to do so could result
in serious injury.
6.
See Figure 2-98. Gently apply low pressure compressed
air to banjo bolt hole (3) to force pistons from caliper
bores.
7.
Remove brake pad pin and brake pad.
8975
4
2
2
4
1
1.
Low pressure air nozzle
2.
Brake caliper
3.
Banjo bolt hole
4.
Brake pad
Figure 2-98. Removing Pistons
3
8987
2
1.
Brake caliper
2.
Brake pad pin
3.
Brake pad friction material
4.
Brake pad backing plate
1
3
Figure 2-97. Preparing Caliper for Piston Removal
8.
See Figure 2-96. Remove both pistons (17) from caliper
bores by hand. If necessary, wiggle pistons gently to
1.
Wooden toothpick
completely remove.
2.
Dust seal
3.
Piston seal
CAUTION
Figure 2-99. Caliper Seals
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.
9.
See Figure 2-99. Using a wooden toothpick (1), remove
dust seal (2) and piston seal (3) from each caliper bore.
Discard seals.
10. See Figure 2-96. If necessary, remove bleeder valve
(10).
2-62
2006 Sportster: Chassis
HOME
CLEANING, INSPECTION AND
1WARNING
REPAIR
Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation
could result in death or serious injury. (00111a)
1WARNING
5. Inspect brake pads and brake disc. Replace if necessary.
Always use denatured alcohol to clean metal brake sys-
tem components and HARLEY-DAVIDSON D.O.T.
5
a. See 1.10 BRAKE PADS AND DISCS for specifica-
BRAKE FLUID to clean rubber brake system compo-
tions.
nents. Do not use mineral-base cleaning solvents, such
b. See FRONT WHEEL under 2.4 WHEELS for brake
as gasoline or paint thinner. Use of mineral-base sol-
disc replacement procedure.
vents causes deterioration of rubber parts that continues
after assembly. This may result in improper brake opera-
ASSEMBLY
tion which could result in death or serious injury.
1.
See Figure 2-96. Wipe old lubrication from inside of cali-
per pin boot (2) and caliper bushing boot (12) with a soft,
CAUTION
clean cloth.
2.
Clean all other rubber parts with HARLEY-DAVIDSON
Use ONLY KS62F assembly grease for lubrication. Use of
D.O.T. 5 BRAKE FLUID. Do not contaminate with mineral
D.O.T. 5 brake fluid will result in increased brake lever
oil or other solvents. Clean all metal parts with denatured
travel.
alcohol. Wipe parts dry with a clean, lint free cloth.
1. Lubricate the following parts prior to assembly using a
light coat of KS62F assembly grease from the service
1WARNING
parts kit. All other surfaces must be dry for assembly.
a. Nose radius of pistons. See Figure 2-100.
Compressed air can pierce the skin and flying debris
from compressed air could cause serious eye injury.
b. All surfaces of piston seals and dust seals.
Wear safety glasses when working with compressed air.
Never use your hand to check for air leaks or to deter-
mine air flow rates. (00061a)
10396
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 pistons (17) for pitting, scratching or corro-
sion on outside surfaces.
b. Inspect caliper piston bores. Do not hone bores. If
bores show pitting or corrosion, replace caliper.
c. Inspect pad pin (14) for grooving and wear. Measure
the pad pin diameter in an unworn area, and then in
Figure 2-100. Piston Nose Radius
the area of any grooving or wear. If wear is more
than 0.011 in. (0.28 mm), replace pad pin.
d. Inspect caliper bolt pin (4). If damaged or exces-
CAUTION
sively worn, replace brake caliper assembly.
e. Inspect caliper bushing boot and caliper pin boot. If
Damaged piston bores will leak when reassembled. Do
worn or damaged, replace.
not use metal objects to remove or install objects in pis-
ton bores. Prevent damage to bores by only using a
f.
Always replace all seals after disassembly.
wooden toothpick when servicing calipers.
2006 Sportster: Chassis
2-63
HOME
2.
See Figure 2-99. Install a new piston seal (3) and a new
10352
dust seal (2) into each piston bore.
5
4
3.
Carefully insert pistons by hand, nose radius first (see
2
Figure 2-100.), into caliper bores. If installation shows
resistance, remove piston(s) and check that seals are
properly installed and fully seated in grooves.
6
4.
See Figure 2-96. Install bleeder valve (10) on caliper
housing if removed. Tighten bleeder valve to 35-61 in-
lbs (4.0-6.9 Nm).
1
5.
See Figure 2-101. Place caliper housing on workbench
3
as shown. Install pad spring in channel. Press firmly into
place.
1.
Front brake caliper
2.
Caliper mounting bracket
3.
Caliper bushing boot
8971
4.
Caliper pin boot
5.
Caliper bolt pin
6.
Bracket bolt pin
Figure 2-102. Lubricating Caliper Boots and Pins
10353
2
6
3
Figure 2-101. Front Caliper Pad Spring
4
5
LUBRICATING FRONT CALIPER
1
BOLT PINS AND BOOTS
10354
7
5
4
1.
See Figure 2-102. Apply approximately 0.4 g of G40M
BRAKE GREASE inside caliper bushing boot (3) and cal-
iper pin boot (4).
2.
See Figure 2-103. Apply G40M BRAKE GREASE inside
boot lip (8) to prevent sticking between boots (3, 4) and
bolt pins (5, 6).
3.
Assemble brake caliper and mounting bracket, carefully
sliding bolt pins into boots. Slide brake caliper all the way
8
onto mounting bracket until boot lips fit over tapered
1
2
shoulders (7) of bolt pins.
1.
Front brake caliper
2.
Caliper mounting bracket
3.
Caliper bushing boot
4.
Caliper pin boot
5.
Caliper bolt pin
6.
Bracket bolt pin
7.
Tapered shoulder
8.
Boot lip
Figure 2-103. Assembling Front Brake
Caliper and Mounting Bracket
2-64
2006 Sportster: Chassis
HOME
INSTALLING BRAKE PADS IN
INSTALLATION
CALIPER
1. See Figure 2-105. If servicing a vehicle with a single
front brake caliper, advance to the next step. On models
NOTE
with dual front brakes, align calipers to brake discs.
The front left and front right (not present on all vehicles) cali-
a. Tighten axle nut to 50-55 ft-lbs (67.9-74.6 Nm).
pers do NOT use the same exact brake pad set as the rear
b. Loosen axle pinch bolt nuts.
brake caliper.
c. Insert 7/16 in. drill bit (2) into hole in axle (1) as far
1.
See Figure 2-104. Insert one set of brake pads (1) into
as it will go.
caliper with friction material on pad facing opening for
d. Position fork leg against edge of drill bit. Contact
brake disc. Curved portion of pad fits into recessed area
point (3) must the have edge of drill bit touching the
of caliper. Make sure brake pad front mounting tab (2) fits
edge of fork leg.
into slot (5) in caliper mounting bracket (4).
e. Tighten axle pinch screw to 21-27 ft-lbs (28.5-36.6
2.
See Figure 2-96. Press brake pads (8) tightly up against
Nm) and withdraw drill bit.
pad spring (16) and install pad pin (14). Tighten to 131-
173 in-lbs (14.8-19.6 Nm).
NOTES
10351
If pad pin does not fit, check the following:
2
● You are using a set of pads, not two identical pads.
● Pad spring orientation must match Figure 2-101.
● See Figure 2-104. Pad front mounting tabs (2) must be
fully seated in mounting bracket slot (5).
1
● Pads must be pushed tight up against pad spring before
pad pin is installed.
3.
See Figure 2-96. Install pad pin plug (13). Tighten to 18-
3
25 in-lbs (2.0-2.9 Nm).
8972
1.
Axle
2
3
3
2.
Drill bit
3.
Contact point
Figure 2-105. Dual Brake Disc Alignment
1
1
10344
2
5
4
1.
Brake pad
2.
Front mounting tab
3.
Pad pin hole
4.
Front caliper mounting bracket
5.
Slot
Figure 2-104. Front Brake Pads
2006 Sportster: Chassis
2-65
HOME
2.
See Figure 2-106. Place brake caliper (4) with mounting
4.
See Figure 2-107. Remove cover screws (3), top cover
bracket (5) over brake disc with bleeder valve (7) facing
(2) and gasket from front brake master cylinder reservoir
upwards. Install mounting bolts (6) into mounting holes
(1).
on fork leg. Tighten to 28-38 ft-lbs (38.0-51.6 Nm).
8966
3
10340
7
3
6
2
2
1
5
1.
Front brake master cylinder and reservoir
1
2.
Top cover
3.
Cover screw (2)
Figure 2-107. Removing Master Cylinder Reservoir Cover
4
NOTES
1.
Banjo bolt
●
See Figure 2-108. Do not use sight glass to determine
2.
Washer (2)
maximum fluid level. Sight glass should only be used as
3.
Front brake line
a visual indicator that fluid level is low and needs atten-
4.
Brake caliper
tion.
5.
Caliper mounting bracket
6.
Mounting bolt (2) (12 pt/10 mm)
●
Use only HARLEY-DAVIDSON D.O.T. 5 BRAKE FLUID
7.
Bleeder valve
from a sealed container.
●
Do not overfill reservoir. Do not reuse old brake fluid.
Figure 2-106. Front Caliper Assembly
10444
CAUTION
1
To avoid leakage, verify that washers, banjo bolt, brake
line and caliper bore are completely clean.
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.
3.
Position a new washer (2) on each side of hydraulic
brake line (3) banjo fitting. Insert banjo bolt (1) through
washers and fitting. Thread bolt into caliper housing.
Tighten to 20-25 ft-lbs (27.1-33.9 Nm).
2
1WARNING
Direct contact of D.O.T. 5 brake fluid with eyes can cause
1.
Cast-in ridge
eye irritation, swelling, and redness. Avoid eye contact.
2.
Sight glass
In case of eye contact flush with large amounts of water
and get medical attention. Swallowing large amounts of
Figure 2-108. Filling Front Master Cylinder Reservoir
D.O.T. 5 brake fluid can cause digestive discomfort. If
swallowed, obtain medical attention. Use in well venti-
lated area. KEEP OUT OF REACH OF CHILDREN.
(00144a)
2-66
2006 Sportster: Chassis
HOME
5.
See Figure 2-108. Add enough HARLEY-DAVIDSON
8. See Figure
2-108. Add enough HARLEY-DAVIDSON
D.O.T. 5 BRAKE FLUID to reservoir to bring fluid level
D.O.T. 5 BRAKE FLUID to reservoir to bring fluid level
even with ridge cast into inside of reservoir, about 0.25
even with ridge cast into inside of reservoir, about 0.25
in. (6 mm) below top edge.
in. (6 mm) below top edge.
9. Install gasket and cover on master cylinder. Tighten
1WARNING
cover screws to 9-17 in-lbs (1.0-2.0 Nm).
10. Tighten front axle and slider cap nuts if necessary.
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
1WARNING
result in death or serious injury. (00289a)
After repairing the brake system, test brakes at low
6.
Bleed brake system. See 1.9 BLEEDING HYDRAULIC
speed. If brakes are not operating properly, testing at
BRAKE SYSTEM.
high speeds can cause loss of control, which could
result in death or serious injury. (00289a)
NOTE
On models with dual front brake calipers, make sure to per-
11. Test brake system.
form brake system bleeding procedure on both calipers.
a. Turn ignition switch ON. Squeeze brake hand lever
to verify operation of the brake lamp.
1WARNING
b. Test ride the motorcycle. If the brakes feel spongy,
bleed the system again. See
1.9 BLEEDING
A plugged or covered relief port can cause brake drag or
HYDRAULIC BRAKE SYSTEM.
lock-up, which could lead to loss of control, resulting in
death or serious injury. (00288a)
NOTE
Avoid making hard stops for the first 100 miles (160 km). This
7.
Verify proper operation of master cylinder relief port. With
allows the new pads to become conditioned to the brake
motorcycle positioned so that master cylinder reservoir is
discs.
level, squeeze brake lever slowly with reservoir cover
removed. A slight spurt of fluid will break the surface if all
internal components are working properly.
2006 Sportster: Chassis
2-67
HOME
REAR BRAKE CALIPER
2.15
REMOVAL
10624
2
7
NOTE
If only replacing brake pads, do not remove rear brake cali-
per. For brake pad replacement only, see 1.10 BRAKE PADS
5
AND DISCS.
6
1
1WARNING
Direct contact of D.O.T. 5 brake fluid with eyes can cause
eye irritation, swelling, and redness. Avoid eye contact.
8
In case of eye contact flush with large amounts of water
and get medical attention. Swallowing large amounts of
3
4
D.O.T. 5 brake fluid can cause digestive discomfort. If
swallowed, obtain medical attention. Use in well venti-
1.
Banjo bolt
lated area. KEEP OUT OF REACH OF CHILDREN.
2.
Washer (2)
(00144a)
3.
Rear brake line
4.
Brake caliper
5.
Caliper mounting bracket
CAUTION
6.
Pad pin plug
Damaged banjo bolt surfaces will leak when reassembled.
7.
Bleeder valve
Prevent damage to seating surfaces by carefully removing
8.
Damper
brake line components.
Figure 2-109. Rear Caliper Assembly
1.
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.
2.
See Figure 2-109. Remove the banjo bolt (1) and both
10339
washers (2) to detach rear brake line (3) from brake cali-
per (4). Discard washers.
3.
Remove pad pin plug (6).
4.
See Figure 2-110. Unscrew and remove brake pad pin.
5.
See Figure 2-111. Remove brake pads (15).
6.
Unscrew and remove caliper bolt pin (7).
7.
Slide brake caliper on rear bolt pin (5), away from brake
disc as far as possible.
Figure 2-110. Brake Pad Pin (Plug Removed)
2-68
2006 Sportster: Chassis
HOME
x0562a2x
11
15
10
9
13
12
14
8
2
7
19
16
6
17
18
5
20
4
3
1
1.
Caliper mounting bracket
11. Bleeder nipple cap
2.
Pad spring
12. Bleeder valve
3.
Caliper pin boot
13. Brake pad (2)
4.
Damper
14. Pad retainer (2)
5.
Bolt pin (mounting bracket)
15. Brake pad set
6.
Caliper body
16. Piston
7.
Bolt pin (caliper)
17. Piston seal
8.
Caliper bushing boot
18. Dust seal
9.
Pad pin plug
19. Piston kit
10. Pad pin
20. Retainer bracket (not sold)
Figure 2-111. Rear Brake Caliper Assembly
2006 Sportster: Chassis
2-69
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