Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 9
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6.
See Figure 2-47. With all forty spokes inserted in hub,
9. Straighten any spokes that were accidentally bumped or
group all spokes on top flange into two bundles. Secure
moved on the bottom flange.
each group with throttle grips to keep the spokes
10. Work with the bottom flange of outer spokes (short-head)
together.
first. See Figure 2-49. Using the spoke alignment method
discussed previously, Locate a spoke hole in the rim
pointing downward and outward toward the bottom
x0638x2x
flange of outer spokes (short-head).
a. Verify outer spoke (short-head) reaches the spoke
nipple and secure spoke loosely by hand. Skip three
rim holes and repeat lacing. Follow pattern to com-
plete bottom flange outer spokes (short-head).
b. See Figure 2-50. Once you have completed lacing
the bottom row of outer spokes (short-head) double
check for three empty holes in between each spoke.
x0639x2x
Figure 2-47. Bundling Top Spokes
7.
Make sure all spokes on brake-side flange are still
arranged properly and pointing in the right direction:
a. Swing all outer spokes (short-head) clockwise.
b. Swing the inner spokes (long-head) counterclock-
wise, crossing over the outer spokes (short-head).
c. Angle all spokes as far as they will go without over-
lapping the next LIKE spoke. For instance, swing an
inner spoke
(long-head) counterclockwise across
four spokes as far as it will go before crossing
another inner spoke (laced in a cross-four pattern).
NOTES
Figure 2-49. Beginning Spoke-Bottom Flange Outer
●
All inside spokes lay over all outside spokes.
●
See Figure 2-48. The valve stem hole is centered on the
rim; you do not have to worry about choosing the correct
x0640x2x
relationship between the rim and the hub.
8.
Center the rim over the hub assembly.
x0373x2x
Figure 2-50. Completed Spokes-Bottom Flange Outer
Figure 2-48. Valve Stem Hole Location
NOTE
It is recommended that you lace the first spoke next to the
valve stem hole. When lacing your first spoke, place spoke
nipples through several rim holes to determine the correct
lacing direction. Only one spoke will fit into the spoke nipple
correctly. When connecting the spoke to the spoke nipple, fin-
ger tighten two to three threads.
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2006 Sportster: Chassis
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11. Work with bottom flange inner spokes (long-head) next.
12. See Figure 2-53. Undo each top bundle and fan the
Choose a beginning spoke closest to the valve stem
spokes out (in a starburst pattern) around the top rim
hole.
edge.
a. See Figure
2-51. Each inner spoke
(long-head)
crosses four outer spokes (short-head).
x0643x2x
b. See Figure 2-52. Verify inner spoke reaches spoke
nipple and secure spoke loosely by hand. Skip every
other hole and repeat lacing. Follow pattern to com-
plete bottom row inner spokes (long-head).
x0641x2x
Figure 2-53. Fanning Top Flange Spokes
13. See Figure 2-54. Point all the top flange inner spokes
(long-head) clockwise one at a time leaving the outer
spokes (short-head) resting on the rim.
Figure 2-51. Beginning Spoke-Bottom Flange Inner
x0644x2x
x0642x2x
Figure 2-54. Setting Top Flange Inner Spokes
NOTE
Figure 2-52. Completed Spokes-Bottom Flange Inner
Do not knock outer spokes (short-head) under inner spokes
(long-head) or they will be trapped underneath the inner row
of spokes.
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14. Using the spoke alignment method discussed previously,
15. See Figure 2-57. Finish with top flange outer spokes
choose a beginning spoke closest to the valve stem hole.
(short-head). Point the top flange outer spokes (short-
Start with top flange inner spokes (long-head) first.
head) counterclockwise and make sure each one
crosses four inner spokes before securing it to the rim.
a. See Figure 2-55. Verify spoke reaches spoke nipple
and secure spoke by hand. Follow pattern to com-
plete top flange inner spokes (long-head).
x0647x2x
b. See Figure 2-56. Once you have completed the top
flange of inner spokes (long-head) double check for
one empty hole after every third spoke.
x0645x2x
Figure 2-57. Beginning Spoke-Top Flange Outer
16. See Figure 2-58. Verify spoke reaches spoke nipple and
secure spoke by hand. Follow pattern to complete top
flange outer spokes (short-head).
Figure 2-55. Beginning Spoke-Top Flange Inner
x0648x2x
x0646x2x
Figure 2-58. Completed Spokes-Top Flange Outer
Figure 2-56. Completed Spokes-Top Flange Inner
17. Verify that all outer (short head) spokes on top flange
point counterclockwise, and all outer spokes on bottom
flange point clockwise. Verify that all inner (long head)
spokes on top flange point clockwise, and all inner
spokes on bottom flange point counterclockwise.
18. Tighten spoke nipples to 40-50 in-lbs (4.5-5.7 Nm).
19. True the wheel. See 2.8 TRUING LACED WHEELS.
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TRUING LACED WHEELS
2.8
PROCEDURE
x0635x2x
Rim
PART NO.
SPECIALTY TOOL
HD-99500-80
Wheel truing stand
HD-94681-80
Spoke wrench
1.
See 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.
Hub
1464
1
2
Figure 2-60. Centering Chrome
Aluminum Profile Laced Wheel
x0392x2x
4
3
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 enter-
ing rim hole.
2.
Finger tighten the spokes in these four groups. Leave all
other spokes loose.
x0393a2x
3.
Install truing arbor in wheel hub and place wheel in
A
WHEEL TRUING STAND. 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 centering the profile wheel is
shown in Figure 2-60.
Figure 2-61. Centering 16-in. hub
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4.
See Figure 2-61. See Figure 2-62. Refer to Table 2-14.
The hub must be centered sideways with the rim. Lay a
1469
straightedge across the hub brake disc flange and one of
the marked spoke groups. Measure the distance from
the straightedge to the rim as shown. If this dimension is
not equal on both sides of the wheel, loosen and tighten
the four spokes accordingly. Use SPOKE WRENCH.
NOTE
See Figure 2-61. See Figure
2-62. Refer to Table 2-14.
Dimension “A” must be maintained to ensure centering of
wheel on motorcycle.
EXAMPLE
If the measurement on the rim right side is greater than the
left side, 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
x0394a2x
19 in.
Always loosen the appropriate two spokes before tightening
A
the other two. Reversing this procedure will cause the rim to
become out-of-round.
Repeat Step 4 for all four groups on the wheel.
Table 2-14. Hub Centering Dimensions
x0074x7x
21 in.
A
RIM
DIMENSION A VALUE
TYPE
SIZE
IN.
MM
16 in.
1.472-1.492
37.389-37.897
Steel laced
19 in.
0.837-0.857
21.260-21.768
21 in.
0.719-0.739
18.263-18.771
Figure 2-62. Centering 19-in and 21-in Hub
Chrome
16 in.
1.190-1.210
30.226-30.734
aluminum
21 in.
0.749-0.769
19.025-19.533
profile laced
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2006 Sportster: Chassis
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5.
See Figure 2-63. After rim has been centered sideways it
6. Spin the rim slowly.
must be checked and trued radially. Adjust truing stand
a. If the rim contacts the gauge on or near a marked
gauge to the rims tire bead seat as shown. The rim
group of spokes, loosen the spokes in the marked
should be trued within 0.030 in. (0.76 mm).
group on the opposite side of the rim. Now tighten
the spokes in the group where the rim makes con-
tact. Loosen and tighten spokes an equal number of
x0395x2x
turns.
b. 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.
7. 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 alternately until they are snug.
8. Seat each spoke head in the hub flange using a flat nose
punch and hammer. Then check wheel trueness again
and tighten the nipples accordingly.
CAUTION
Overtightening spokes may cause nipples to be drawn
through rim, or hub flanges to be distorted. Spokes left
too loose continue to loosen when wheel is put into ser-
vice. Loose spokes will also lead to breakage of adjacent
tight spokes, which are carrying a larger share of the
Radial
load.
runout
9. File or grind off ends of spokes protruding through nip-
ples to prevent puncturing tube when tire is mounted.
10. See Figure 2-61. See Figure 2-62. Refer to Table 2-14.
Gauge
Spoke nipple
Check dimension A and re-true wheel if not within speci-
wrench
fications.
Figure 2-63. Truing Rim Radially
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CHECKING CAST WHEEL RUNOUT
2.9
2. See Figure 2-65. Check for radial runout as shown.
CHECKING LATERAL AND RADIAL
Replace the wheel if runout exceeds
0.030 in.
RUNOUT
(0.76 mm).
x0397a2x
PART NO.
SPECIALTY TOOL
HD-99500-80
Wheel truing stand
Check cast wheels for lateral and radial runout before install-
ing a new tire.
1.
See Figure 2-64. Install truing arbor in wheel hub and
place wheel in WHEEL TRUING STAND. Tighten arbor
nuts so hub will turn on its bearings. To check wheel lat-
eral runout, place a gauge rod or dial indicator near the
rim bead. If lateral runout exceeds 0.040 in. (1.02 mm),
replace the wheel.
x0396a2x
Figure 2-65. Checking Cast Wheel Radial Runout
Figure 2-64. Checking Cast Wheel Lateral Runout.
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TIRES
2.10
GENERAL
x0188a2x
PART NO.
SPECIALTY TOOL
HD-01289
Rim protector
HD-21000
Tire spreader
HD-20000
Tire repair kit
HD-28700
Bead expander
HD-99500-80
Wheel truing stand
Tires should be inspected for punctures, cuts, breaks and
wear at least weekly.
Figure 2-66. Loosening Beads from Rim Flange
Whenever a tire on a laced wheel is replaced, the tube should
also be replaced. Inner tubes should be patched only as an
6. On tubeless tire rims, remove the valve stem if it is dam-
emergency measure. Replace a damaged or patched tube as
aged or leaks.
soon as possible. Rim bands must be used on all laced
wheels.
x0187a2x
Some tires have arrows molded into the tire sidewall. These
tires should be mounted on the rim with the arrow pointing in
the direction of forward rotation. The colored dot on the side-
wall is a balance mark and should be located next to the valve
stem hole.
1WARNING
Always check both tire sidewalls for arrows indicating
forward rotation. Some tires require different tire rotation
depending on whether tire is used on front or rear wheel.
Failure to observe this warning may lead to tire failure
which could result in death or serious injury.
REMOVAL
1.
Remove wheel from motorcycle. See 2.4 WHEELS.
2.
Deflate tire.
3.
See Figure 2-66. Loosen both tire beads from rim flange.
Figure 2-67. Starting Tire Off Rim
In most cases, a bead breaker machine will be required
to loosen the beads from the rim.
NOTE
4.
If a bead breaker machine is not available, attach RIM
On tube type wheels, it is not necessary to completely
PROTECTORS to the rim. Using tire tools (not sharp
remove tire from rim. Removing one side allows the tube to
instruments), start upper bead over edge of rim at valve.
be replaced and allows for inspection of tire.
Repeat all around rim until first bead is over rim. Remove
the tube on tube type wheels.
7. Mount the tire on TIRE SPREADER for inspection and
repair procedures.
CAUTION
Do not use excessive force when starting bead over rim.
Excessive force may damage wires in tire bead.
5.
See Figure 2-67. Push lower bead into rim well on one
side and insert tire tool underneath bead from opposite
side. Pry bead over rim edge. Remove tire from rim.
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CLEANING, INSPECTION AND
1556
REPAIR
1.
Clean the inside of tire and outer surface of tube.
2.
If rim is dirty or rusty, clean with a stiff wire brush.
3.
Inspect the tire and tube for wear and damage. Replace
worn tires. Replace damaged tubes. Use TIRE REPAIR
KIT for tire repair. Follow the kit manufacturer's instruc-
tions.
INSTALLATION
Tube Type Tires
1WARNING
Match tires, tubes, air valves and caps to the correct
wheel rim. Contact a Harley-Davidson dealer. Mismatch-
ing can result in damage to the tire bead, allow tire slip-
page on the rim or cause tire failure, which could result
in death or serious injury. (00023a)
NOTE
Figure 2-68. Installing Rim Strip
For correct tire and tube types, see TIRES under 2.1 SPECI-
FICATIONS.
x0668x2x
1.
See Figure 2-68. On laced wheels, install a rim strip into
the rim well. Make sure no spokes protrude through nip-
ples, and be sure to align the valve stem hole in rim strip
with valve stem hole in rim.
2.
Thoroughly lubricate the rim flanges and both beads of
the tire with tire lubricant.
3.
See Figure 2-69. Starting at the valve stem hole, start
the first bead into the rim well. Work the bead on as far
as possible by hand. Use the tire tool to pry the remain-
ing bead over the rim flange.
4.
Inflate tube just enough to round it out. Lubricate thor-
oughly 360 degrees around the tube base. Insert tube in
tire with valve stem in hole.
5.
Starting 180 degrees from valve stem, start the second
bead onto the rim. Work the bead onto the rim with tire
tools, working toward valve in both directions. Remove
the valve core from valve stem before prying the remain-
ing bead over the rim flange.
Figure 2-69. Starting Bead on Rim
6.
Make sure valve stem moves in and out freely, then
inflate the tire to recommended pressure to seat the
bead. See 2.1 SPECIFICATIONS. Then deflate tire to
allow inner tube to smooth out. Install the valve core,
then inflate to recommended pressure.
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2006 Sportster: Chassis
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Tubeless Tires
x0199a2x
1
1WARNING
2
Only install original equipment tire valves and valve
caps. A valve, or valve and cap combination, that is too
long or too heavy can strike adjacent components and
damage the valve, causing rapid tire deflation. Rapid tire
deflation can cause loss of vehicle control, which could
result in death or serious injury. (00281a)
3
1.
See Figure 2-70. On tubeless wheels, damaged or leak-
ing valve stems must be replaced. Install rubber grom-
met (3) on valve stem.
2.
Insert valve stem into rim hole.
3.
Install metal washer (2).
1.
Nut
4.
Install nut and tighten to 12-15 in-lbs (1.4-1.7 Nm).
2.
Metal washer
3.
Rubber Grommet
5.
Thoroughly lubricate the rim flanges and both beads of
the tire with tire lubricant.
Figure 2-70. Tubeless Tire Valve Stem
6.
See Figure 2-69. Starting at the valve stem, start the first
bead into the rim well. Work the bead on as far as possi-
CHECKING TIRE RUNOUT
ble by hand. Use a tire tool to pry the remaining bead
over the rim flange.
7.
Start 180 degrees from the valve stem hole and start the
Lateral Runout
second bead on the rim. Work the bead onto the rim with
1. See Figure
2-71. Turn wheel on axle and
measure
tire tools, working toward the valve in both directions.
amount of displacement from a fixed point to tire side-
8.
Apply air to the valve stem to seat the beads on the rim.
wall.
It may be necessary to use BEAD EXPANDER on the
2. Tire tread lateral runout should be no more than 0.080 in.
tire until the beads seal on the rim.
(2.03 mm). If runout is more than 0.080 in. (2.03 mm),
remove tire from rim, and check rim bead side runout to
1WARNING
see if rim is at fault.
3. If rim bead seat runout is less than 0.030 in. (0.76 mm),
Do not exceed manufacturer's recommended pressure to
then tire is at fault and must be replaced. If rim bead seat
seat beads. Exceeding recommended bead seat pres-
runout is greater than 0.030 in. (0.76 mm), correct by
sure can cause tire rim assembly to burst, which could
tightening selected spoke nipples
(laced wheels) or
result in death or serious injury. (00282a)
replace wheel (cast wheels). Install tire and check tire
tread radial runout again.
NOTE
Maximum safe inflation pressure is 40 psi (2.8 bars). If the
beads fail to seat at 40 psi (2.8 bars), deflate and re-lubricate
the bead and rim and reinflate to seat the beads.
x0398a2x
Figure 2-71. Checking Tire Lateral Runout
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Radial Runout
Weights For Laced Wheels
1.
See Figure 2-72. Turn wheel on axle and measure tread
Harley-Davidson specifies the following spoke balance
radial runout.
weights, which are crimped over the spoke nipple.
2.
Tire tread radial runout should not be greater than 0.090
Table 2-15. Laced Wheel Balance Weights
in. (2.29 mm). If runout exceeds specification, remove
tire from rim and check rim bead runout to determine if
WEIGHT (MASS)
HD PART NUMBER
rim is at fault.
1/2 oz. (U.S.)
14 g
95578-41
3.
If rim bead seat runout is less than 0.030 in. (0.76 mm),
then tire is at fault and must be replaced. If rim bead seat
3/4 oz. (U.S.)
21 g
95581-47
runout is greater than 0.030 in. (0.76 mm), correct by
1 oz. (U.S.)
28 g
95582-47
tightening selected spoke nipples
(laced wheels) or
replace wheel (cast wheels). Install tire and check tire
Weights for Cast Wheels
tread radial runout again.
Harley-Davidson specifies the following cast wheel balance
weights, which have special self-adhesive backings.
x0399a2x
Table 2-16. Cast Wheel Balance Weights
WEIGHT (MASS)
FINISH
HD PART NUMBER
oz. (U.S.)
grams
1/4
7
black
95594-84
1/4
7
silver
95595-84
These weights are applied to the flat surface of the wheel rim
according to the following procedures.
1. Make sure that area of application is completely clean,
dry, and free of oil and grease.
NOTE
If 1 oz. (28 g) or more of weight must be added at one loca-
tion, split the amount so that half is applied to each side of
rim.
2. Remove paper backing from weight. Apply three drops of
Figure 2-72. Checking Tire radial Runout
LOCTITE® SUPERBONDER® 420 to the adhesive side
of the weight. Place the weight on flat surface of wheel
WHEEL BALANCING
rim. Press weight firmly in place, and hold for ten sec-
onds.
Wheel balancing is recommended to improve handling, and
3. Allow eight hours for adhesive to cure completely before
to reduce vibration, especially at high road speeds.
using wheel.
In most cases, static balancing using WHEEL TRUING
STAND will produce satisfactory results. However, dynamic
balancing, utilizing a wheel spinner, can be used to produce
finer tolerances for best high-speed handling characteristics.
Follow the instructions supplied with the balance machine
you are using.
The maximum weight permissible to accomplish balance is
3-1/2 oz.
(866 g)
(total weight applied to the rim).
Wheels should be balanced to within 1/2 oz. (14 g) at 60
m.p.h. (97 km/h).
2-40
2006 Sportster: Chassis
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FRONT BRAKE MASTER CYLINDER
2.11
GENERAL
REMOVAL
The front brake master cylinder designed for dual disc (two
1.
See Figure 2-74. Loosen turn signal clamp screw (3) and
caliper) operation has a larger bore than the master cylinder
remove turn signal assembly (5) from front brake master
designed for single disc (one caliper) operation.
cylinder housing (1).
See Figure 2-73. The bore size is cast into the side of the
2.
Loosen and remove lock nut and washer (4), and lift mir-
master cylinder body facing the handlebar.
ror (2) from master cylinder housing.
● The single disc master cylinder has “1/2” (1/2 inch) cast
into the body.
8966
● The dual disc master cylinder has “14” (14 mm) cast in.
2
1
8
1WARNING
7
Do not use a single disc master cylinder assembly on
dual disc (two caliper) models. Likewise, do not use a
3
dual disc master cylinder assembly on single disc (one
caliper) models. These master cylinder assemblies are
not interchangeable. Using the wrong assembly can
4
adversely affect braking efficiency or result in brake fail-
ure causing death or serious injury.
5
6
10378
1. Front brake master cylinder and reservoir
2. Mirror
3. Turn signal clamp screw
4. Lock nut and washer
5. Turn signal assembly
6. Front brake line banjo fitting
7. Banjo bolt
8. Washer (2)
Figure 2-74. Front Brake Master Cylinder
Figure 2-73. Verifying Front Brake Master Cylinder
Bore Size (Single Disc Master Cylinder Shown)
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4. See Figure 2-74. Remove banjo bolt (7) and two washers
1WARNING
(8) to disconnect hydraulic brake line banjo fitting (6)
from master cylinder (1). Discard washers.
Direct contact of D.O.T. 5 brake fluid with eyes can cause
5. See Figure 2-77. Squeeze front brake lever and place a
eye irritation, swelling, and redness. Avoid eye contact.
5/32 inch (4 mm) thick cardboard insert between brake
In case of eye contact flush with large amounts of water
lever and lever bracket. Release brake lever.
and get medical attention. Swallowing large amounts of
D.O.T. 5 brake fluid can cause digestive discomfort. If
swallowed, obtain medical attention. Use in well venti-
10383
lated area. KEEP OUT OF REACH OF CHILDREN.
(00144a)
3.
See Figure 2-75. See Figure 2-76. Remove bleeder nip-
ple 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.
10340
3
Figure 2-77. Install Cardboard Insert
Before Removing Master Cylinder Assembly
2
1
CAUTION
Do not remove the master cylinder assembly without first
1.
Front brake caliper
placing the 5/32 inch (4 mm) cardboard insert between
2.
Bleeder nipple cap
the brake lever and lever bracket. Removal without the
3.
Bleeder valve
insert may result in damage to the rubber boot and
plunger of the front stoplight switch.
Figure 2-75. Front Caliper Bleeder Valve
NOTE
Use the eyelet of an ordinary cable strap if the cardboard
x0419a2x
insert is not available.
6. See Figure 2-78. Using a T-27 TORX drive head, remove
the two screws (6) and washers (7) securing the handle-
bar clamp (8) to the master cylinder housing (5). Remove
the brake lever/master cylinder assembly and clamp from
the handlebar.
Figure 2-76. Bleeding Hydraulic System
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2006 Sportster: Chassis
HOME
x0401b2x
Provided in Service Parts Kit
1
NOTE: there are two service parts kits; one for
2
single-disc master cylinders and one for dual
disc master cylinders. Consult your parts cat-
alog for the correct part number of the kit you
require.
3
9
4
6
7
5
8
10
Single disc
piston assembly
19
11
12
13
15
14
17
Dual disc
piston assembly
18
16
20
1.
Screw (2)
11.
Spring
2.
Reservoir cover
12.
Primary cup
3.
Diaphragm plate
13.
Secondary cup
4.
Diaphragm
14.
Piston
5.
Master cylinder housing
15.
Retaining ring
6.
Screw (2)
16.
Dust boot
7.
Washer (2)
17.
Retaining ring
8.
Handlebar clamp
18.
Brake hand lever
9.
Pivot pin
19.
Bushing
10.
Brake line banjo fitting seating surface
20.
G40M brake grease
Figure 2-78. Front Brake Master Cylinder Assembly
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DISASSEMBLY
10572
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)
NOTE
Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.
1.
See Figure 2-78. Remove retaining ring (17) from pivot
pin (9) groove at bottom of master cylinder bracket. Dis-
card retaining ring.
2.
Remove pivot pin and brake hand lever (18) from master
Figure 2-79. Clamping Front Master Cylinder
cylinder assembly.
3.
Remove and discard dust boot (16).
NOTE
Use correct retaining ring pliers and correct tips. Verify that
CAUTION
tips are not excessively worn or damaged.
5. See Figure 2-78. Press down on end of piston and
See Figure 2-79. Clamp front brake master cylinder in a
remove retaining ring (15). Discard retaining ring.
vise by the mirror mounting boss only. Use brass or alu-
minum jaw covers or other protective device on vise jaws
6. Remove and discard piston assembly (12, 13, 14) and
to prevent damage to master cylinder.
piston spring (11).
4.
See Figure 2-79. Clamp master cylinder in a vise so that
NOTES
banjo fitting hole is pointing straight down.
● See Figure 2-78. Both primary (12) and secondary (13)
cups are fitted into grooves in the piston body (14) of sin-
gle disc master cylinder pistons. The piston spring (11)
1WARNING
fits onto the end of the piston.
Wear safety glasses or goggles when removing or install-
● Dual disc master cylinder pistons have only the second-
ing retaining rings. Retaining rings can slip from the pli-
ary cup fitted into a groove in the piston body. The pri-
ers and could be propelled with enough force to cause
mary cup fits onto the small end of the piston spring.
serious eye injury. (00312a)
CAUTION
To prevent dirt and other contaminants from entering the
master cylinder reservoir, thoroughly clean the cover
before removal.
7. Remove two screws (1), cover (2), diaphragm plate (3)
and diaphragm (4) from the master cylinder reservoir.
2-44
2006 Sportster: Chassis
HOME
CLEANING, INSPECTION AND
ASSEMBLY
REPAIR
1WARNING
1WARNING
Do not use replacement parts from single disc repair kits
on dual disc models. Likewise, do not use replacement
Compressed air can pierce the skin and flying debris
parts from dual disc repair kits on single disc models.
from compressed air could cause serious eye injury.
Parts are not interchangeable. Using the wrong replace-
Wear safety glasses when working with compressed air.
ment parts can adversely affect braking efficiency or
Never use your hand to check for air leaks or to deter-
result in brake failure causing death or serious injury.
mine air flow rates. (00061a)
NOTES
1.
Clean all metal parts with denatured alcohol. Clean all
● Always reassemble the master cylinder using new parts
rubber parts with HARLEY-DAVIDSON D.O.T. 5 BRAKE
from the correct service repair kit.
FLUID. Do not contaminate with mineral oil or other sol-
vents. Wipe dry with a clean, lint free cloth. Blow out
● HARLEY-DAVIDSON D.O.T. 5 BRAKE FLUID is recom-
drilled passages and piston bore with low pressure com-
mended for lubrication of cylinder bore, cups and seals
pressed air from a clean air supply. Do not use a wire or
prior to assembly.
similar instrument to clean drilled passages in bottom of
reservoir.
CAUTION
1WARNING
See Figure 2-79. Clamp front brake master cylinder in a
vise by the mirror mounting boss only. Use brass jaw
Always use denatured alcohol to clean metal brake sys-
covers or other protective device on vise jaws to prevent
tem components and HARLEY-DAVIDSON D.O.T.
5
damage to master cylinder.
BRAKE FLUID to clean rubber brake system compo-
1. See Figure 2-79. Clamp master cylinder in a vise so that
nents. Do not use mineral based solvents (such as gaso-
banjo fitting hole is pointing straight down.
line and paint thinner) or deterioration of rubber parts
may occur after assembly. Deterioration of components
2. See Figure 2-78. Coat piston bore of master cylinder
may result in premature brake failure, possibly causing
housing (5), piston (14), primary cup (12) and secondary
death or serious injury.
cup (13) with HARLEY-DAVIDSON D.O.T. 5 BRAKE
FLUID.
2.
Carefully inspect all parts for wear or damage and
replace as necessary.
a. Inspect the piston bore in the master cylinder hous-
ing for scoring, pitting or corrosion. Replace the
housing if any of these conditions are found.
b. 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.
c. Inspect diaphragm for cuts, tears or general deterio-
ration. Replace if necessary.
2006 Sportster: Chassis
2-45
HOME
3.
See Figure 2-80. Install piston assembly into master cyl-
5. Install new dust boot (16). Large lip of dust boot fits
inder.
down inside end of piston bore. Small lip of dust boot fits
into groove in end of piston (item 5, Figure 2-80.).
a. Single disc master cylinder: Press small end of pis-
ton spring (4) onto mounting boss (6) on piston (1).
6. Apply approximately 0.1 g G40M BRAKE GREASE (from
Slide piston/spring assembly, flared end of spring
service parts kit) to each of the following two locations:
first, into master cylinder bore so that spring seats
● pivot hole in brake hand lever (18).
against counter bore (recess) at bottom of cylinder.
● end of piston (14).
b. Dual disc master cylinder: Press primary cup (2)
7. Align hole in brake hand lever with hole in master cylin-
onto small end of piston spring (4). Insert flared end
der bracket. From top of assembly, slide pivot pin (9)
of spring into master cylinder bore so that it seats
through bracket and hand lever.
against the counter bore (recess) at bottom. Slide
piston into bore over primary cup/spring assembly.
1WARNING
Wear safety glasses or goggles when removing or install-
10440
ing retaining rings. Retaining rings can slip from the pli-
1
ers and could be propelled with enough force to cause
6
Single Disc
serious eye injury. (00312a)
NOTE
Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.
8. Install new retaining ring (17) in pivot pin groove. Verify
that retaining ring is fully seated in groove.
5
3
2
4
9. Remove master cylinder assembly from vise. Install
cover (2), diaphragm plate (3) and diaphragm (4) on
10441
5
1
master cylinder reservoir. Install two screws (1) to fasten
cover to reservoir, but do not tighten at this time.
10. See Figure 2-81. Squeeze front brake lever and place a
5/32 in. (4 mm) thick cardboard insert between brake
lever and lever bracket. Release brake lever.
Dual Disc
10433
3
2
4
1.
Piston
2.
Primary cup
3.
Secondary cup
4.
Piston spring
5.
Dust boot groove
6.
Piston spring mounting boss (single disc piston)
Figure 2-80. Front Master Cylinder Pistons
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)
Figure 2-81. Install 5/32 in. (4 mm) Cardboard Insert
NOTE
Before Installing Master Cylinder Assembly
Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.
4.
See Figure 2-78. Press down on piston (14) and install
new retaining ring (15). Verify that retaining ring is fully
seated in groove.
2-46
2006 Sportster: Chassis
HOME
NOTES
INSTALLATION
● See Figure 2-83. 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 atten-
CAUTION
tion. A ridge (1) is cast into the inside of the reservoir to
See Figure 2-81. Do not install master cylinder assembly
assist you in determining the correct maximum fluid
without first placing 5/32 inch (4 mm) cardboard insert
level.
(or cable strap eyelet) between brake lever and lever
● Fill master cylinder only with HARLEY-DAVIDSON D.O.T.
bracket. Installation without insert may result in damage
5 BRAKE FLUID from a sealed container.
to rubber boot and plunger of front stoplight switch.
● Do not overfill reservoir. Do not reuse old brake fluid.
1.
See Figure 2-82. Position brake lever/master cylinder
assembly inboard of switch housing assembly (1) engag-
5. See Figure
2-83. Add enough HARLEY-DAVIDSON
ing tab (5) on lower switch housing in slot (4) at top of
D.O.T. 5 BRAKE FLUID to reservoir to bring fluid level
brake lever bracket (3).
even with ridge (1) cast into inside of reservoir, about
2.
See Figure 2-78. Align holes in handlebar clamp (8) with
0.25 in. (6 mm) below top edge.
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
10395
TORX drive head.
3
5
4
CAUTION
To avoid leakage, verify that washers, banjo bolt, brake
line banjo fitting and master cylinder bore are completely
clean.
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.
3.
See Figure 2-74. Position a new washer (8) on each side
of hydraulic brake line banjo fitting (6). Insert banjo bolt
1
2
(7) through washers and fitting. Thread bolt into master
cylinder housing. Tighten to 20-25 ft-lbs (27.1-33.9 Nm).
4.
Position motorcycle so that top of master cylinder reser-
1.
Switch housing assembly
voir is level. See Figure 2-78. Remove two screws (1),
2.
5/32 in. (4 mm) cardboard insert
front master cylinder reservoir cover (2), diaphragm plate
3.
Brake lever bracket
(3) and diaphragm (4).
4.
Slot
5.
Tab
1CAUTION
Figure 2-82. Fitting Brake Lever/Master Cylinder
Direct contact of D.O.T. 5 brake fluid with eyes can cause
to Right Handlebar Switch Housing
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
1WARNING
D.O.T. 5 brake fluid can cause digestive discomfort. If
A plugged or covered relief port can cause brake drag or
swallowed, obtain medical attention. Use in well venti-
lock-up, which could lead to loss of control, resulting in
lated area. KEEP OUT OF REACH OF CHILDREN.
death or serious injury. (00288a)
(00144a)
6. 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 properly.
2006 Sportster: Chassis
2-47
HOME
NOTE
10444
On models with two front brake calipers, repeat steps 7.-12.
1
on second caliper.
13. See Figure
2-83. Add enough HARLEY-DAVIDSON
D.O.T. 5 BRAKE FLUID to reservoir to bring fluid level
even with ridge (1) cast into inside of reservoir, about
0.25 in. (6 mm) below top edge.
14. See Figure 2-78. 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).
2
15. See Figure 2-74. Install mirror (2), secure with lock nut
and washer (4). Position mirror for best rearward visibil-
ity. Tighten lock nut to 96-144 in-lbs (10.9-16.3 Nm).
1.
Cast-in ridge
2.
Sight glass
16. Install turn signal assembly (5). Position so turn signal
lens faces directly forward and turn signal does not strike
Figure 2-83. Filling Front Master Cylinder Reservoir
fuel tank when handlebars are turned full right. Tighten
clamp screw (3) to 96-120 in-lbs (10.9-13.6 Nm).
7.
See Figure 2-75. Install length of 5/16 in. (7.9 mm) I.D.
17. With Ignition/Light Key Switch turned to IGNITION, actu-
clear plastic tubing over front brake caliper bleeder valve
ate front brake hand lever to verify operation of rear
(3). Place free end of tube in a clean container.
brake lamp.
8.
See Figure
2-83. Add enough HARLEY-DAVIDSON
D.O.T. 5 BRAKE FLUID to reservoir to bring fluid level
1WARNING
even with ridge cast into inside of reservoir, about 0.25
in. (6 mm) below top edge.
After repairing the brake system, test brakes at low
9.
Depress and hold brake hand lever to build up hydraulic
speed. If brakes are not operating properly, testing at
pressure.
high speeds can cause loss of control, which could
result in death or serious injury. (00289a)
10. Open front caliper bleeder valve about 1/2-turn. Brake
fluid will flow from bleeder valve through tubing. Close
18. Test ride motorcycle at low speed. If brake feels spongy,
bleeder valve when brake hand lever has moved approx-
repeat bleeding procedure.
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 Steps 8-10 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.
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2006 Sportster: Chassis
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REAR BRAKE MASTER CYLINDER
2.12
3. Check rear brake friction pads and disc for excessive
GENERAL
wear or damage. Replace worn or damaged items.
The rear brake master cylinder is mounted transverse to the
a. See 1.10 BRAKE PADS AND DISCS for specifica-
centerline of the vehicle, beneath the rear fork pivot shaft
tions.
assembly.
b. See BRAKE PAD REPLACEMENT-FRONT under
1.10 BRAKE PADS AND DISCS for brake pad
If the rear brake feels spongy or excessive pedal travel exists
replacement procedure.
or the brake does not work at all:
c. See REAR WHEEL under 2.4 WHEELS for brake
disc replacement procedure.
INSPECTION
4. Check mechanical brake linkage from brake pedal to
master cylinder for damage. Repair or replace worn or
1.
Check the level of fluid in the rear brake reservoir. If it is
damaged items.
low, refill and bleed brake system. See BLEEDING
REAR BRAKE under
1.9 BLEEDING HYDRAULIC
● XL 883, XL 883L, XL 883R and XL 1200R models,
BRAKE SYSTEM.
see RIGHT FOOTREST AND REAR BRAKE
PEDAL ASSEMBLY under 2.33 RIDER FOOT CON-
2.
Check for fluid leaks in the brake line, around banjo fit-
TROLS: XL 883, XL 883L, XL 883R, XL 1200R.
tings or rear brake caliper piston or bleeder valve. Repair
● XL 883C and XL 1200C models, see RIGHT FOOT-
and bleed brake system.
REST AND REAR BRAKE PEDAL ASSEMBLY
a. For brake line replacement procedure, see
2.16
under 2.34 RIDER FOOT CONTROLS: XL 883C, XL
BRAKE LINES.
1200C
b. To repair rear brake caliper, see procedure in 2.15
5. Eliminate any air in the hydraulic brake assembly by
REAR BRAKE CALIPER.
bleeding the system. See BLEEDING REAR BRAKE
under 1.9 BLEEDING HYDRAULIC BRAKE SYSTEM.
c. See BLEEDING REAR BRAKE under 1.9 BLEED-
ING HYDRAULIC BRAKE SYSTEM for hydraulic
If none of these conditions exist but the rear brake system
brake system bleeding procedure.
does not operate properly, the rear master cylinder is most
likely defective and must be repaired or replaced.
2006 Sportster: Chassis
2-49
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