Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Service Manual — page 12
2.8
SEALED WHEEL BEARINGS
INSPECTION
When lifting a motorcycle using a jack, be sure jack con-
tacts both lower frame tubes where down tubes and lower
frame tubes converge. Never lift by jacking on cross-
members, oil pan, mounting brackets, components or
housings. Failure to comply can cause serious damage
resulting in the need to perform major repair work. (00586d)
1.
Raise the wheel with a suitable lifting device.
2.
Turn the wheel through several rotations.
NOTE
If ABS equipped, keep magnetic base dial indicator as far away
from wheel speed sensor and ABS encoder bearing as pos-
sible, or damage will occur.
3.
Check end play as follows:
a.
See
. Mount a magnetic base dial indicator
to the brake disc. Set the indicator contact point on
the end of the axle.
b.
Firmly push the wheel to one side and zero the dial
indicator gauge.
c.
Firmly pull the wheel back as far as it will go and note
the reading of the dial indicator.
d.
Repeat the procedure to verify the reading.
e.
Replace the bearings if end play exceeds 0.002 in.
(0.051 mm), or if there is drag, rough rotation,
abnormal noise or anything unusual.
sm02234
Figure 2-23. Wheel Bearing Inspection (Front Wheel
Shown)
REMOVAL
TOOL NAME
PART NUMBER
25MM BEARING REMOVER (NON-
ABS)
HD-44060-10A
25MM BEARING REMOVER (ABS)
HD-44060-11A
WHEEL BEARING
INSTALLER/REMOVER
HD-44060C
1.
Remove wheel. See
or
2.
If present, remove hub plate from wheel on opposite side
of front brake disc.
NOTES
•
See
. Some wheel hubs may not provide
adequate support for the puller bridge. In these cases
center a used brake disc over the hub to support the puller
bridge while removing the bearings.
•
ABS equipped motorcycles use both a special encoder
bearing (greenish tan in color) on the primary brake disc
side. They use a standard bearing (black) on the opposite
side. Select 25MM BEARING REMOVER (ABS) (Part
No. HD-44060-11A) or 25MM BEARING REMOVER
(NON-ABS) (Part No. HD-44060-10A).
3.
See
Obtain
WHEEL
BEARING
INSTALLER/REMOVER (Part No. HD-44060C) and
assemble using 25MM BEARING REMOVER (ABS) (Part
No. HD-44060-11A) or 25MM BEARING REMOVER
(NON-ABS) (Part No. HD-44060-10A) (6).
a.
Sparingly apply GRAPHITE LUBRICANT to forcing
screw (1) to maintain smooth operation and prolong
service life.
b.
Install nut (2), washer (3) and bearing (4) on screw.
Insert assembly through hole in bridge (5).
c.
Drop ball bearing inside 25 mm collet (6). Fasten collet
and ball bearing to forcing screw.
4.
Hold end of forcing screw and turn collet to expand edges
of collet.
5.
See
. When expanded collet has gripped
bearing edges, hold end of forcing screw and turn the nut
to remove bearing from wheel.
6.
Remove spacer from inside wheel hub.
7.
Repeat procedure for opposite side bearing. Discard all
bearings upon removal.
2013 Softail Service: Chassis 2-25
3
6
1
2
4
5
sm02235
1. Forcing screw
2. Nut
3. Washer
4. Bearing
5. Bridge
6. Collet with ball bearing inside
Figure 2-24. Removal Tool
SM03870
Figure 2-25. Brake Disk as Puller Aid
2-26 2013 Softail Service: Chassis
2
1
sm02236
1. Forcing screw
2. Nut
Figure 2-26. Remove Bearing
INSTALLATION
TOOL NAME
PART NUMBER
WHEEL BEARING
INSTALLER/REMOVER
HD-44060C
NOTES
•
Install first bearing on primary brake disc side of hub, which
is identified by having one or two grooves cut into the disc
mounting surface.
•
Keep ABS encoder bearings away from magnetic fields
(such as magnetic parts trays, magnetic base dial indic-
ators, alternator rotors, etc.) or damage will occur.
•
ABS equipped motorcycles use a special encoder bearing
(greenish tan in color) on the primary brake disc side and
a standard bearing (black) on the opposite side.
1.
Obtain WHEEL BEARING INSTALLER/REMOVER (Part
No. HD-44060C) and assemble.
a.
Sparingly apply graphite lubricant to threads of
threaded rod to prolong service life and maintain
smooth operation.
b.
See
. Place threaded rod through support
plate. Insert assembly through wheel.
c.
See
. Place the
new
bearing (6) on rod
(1) with lettered side facing away from wheel center-
line. ABS bearing with greenish tan side against pilot
(5).
d.
Install pilot (5), bearing (4), washer (3) and nut (2)
over rod.
2.
Hold hex end of threaded rod (1) and turn nut (2) to install
bearing (6) into primary side of hub. Bearing will be fully
seated when nut can no longer be turned. Remove tool.
3.
Install spacer inside wheel hub.
4.
Reverse tool and install opposite side bearing until bearing
contacts inner spacer.
sm02237
Figure 2-27. Installation Tool Support Plate
2
6
4
1
3
5
sm02238
1. Threaded rod
2. Nut
3. Washer
4. Bearing
5. Pilot
6. Wheel bearing
Figure 2-28. Installing Bearing
2013 Softail Service: Chassis 2-27
3
1
5
4
15
12
6
7
2
14
10
9
11
8
13
sm02239
1. Bridge, (Part No. HD-44060-5)
2. Steel ball, (Part No. 12547)
3. Forcing screw, (Part No. HD-44060-4)
4. Nut, (Part No. 10210)
5. Washer, (Part No. 12004)
6. Bearing, (Part No. 217801)
7. Lubricant, (Part No. J-23444A)
8. Collet, 3/4 in, (Part No. HD-44060-3A)
9. Collet (ABS), 25 mm, (Part No. HD-44060-11A)
10. Collet, 1.0 in, (Part No. HD-44060-7)
11. Collet, 25 mm, (Part No. HD-44060-10A)
12. Pilot, 1.0 in, (Part No. HD-44060-8)
13. Support plate, (Part No. HD-44060-1)
14. Pilot, 3/4 in, (Part No. HD-44060-6)
15. Threaded rod, (Part No. 280856)
Figure 2-29. Wheel Bearing Installer/Remover Components
NOTES
•
Parts 1-7 are common to removal and installation.
•
Parts 8-10 are used for removal only.
•
Parts 11-15 are used for installation only.
2-28 2013 Softail Service: Chassis
2.9
TIRES
GENERAL
Use only Harley-Davidson specified tires. See a Harley-
Davidson dealer. Using non-specified tires can adversely
affect stability, handling or braking, which could result in
death or serious injury. (00024b)
Be sure tires are properly inflated, balanced, undamaged,
and have adequate tread. Inspect your tires regularly and
see a Harley-Davidson dealer for replacements. Riding
with excessively worn, unbalanced, improperly inflated,
overloaded or damaged tires can lead to tire failure and
adversely affect stability and handling, which could result
in death or serious injury. (00014b)
Always maintain proper tire pressure as specified in
.
Do not load tires beyond GAWR specified in
or
. Underinflated, over-inflated or overloaded tires can
fail.
NOTES
•
Check runout on all cast or spoke wheels before installing
a new tire. See
2.7 CHECKING AND TRUING WHEELS
.
•
Store new tires on a horizontal tire rack. Avoid stacking
new tires in a vertical stack. The weight of the stack
compresses the tires and closes down the beads.
•
Inspect tires for punctures, cuts, breaks and wear at least
weekly.
•
See
. The tread wear indicator bars will appear
on tire tread surfaces when 1/32 in (0.8 mm) or less of
tread remains. Always replace tires before they reach the
tread wear indicator bars.
New tires are needed if any of the following conditions exist.
See
.
•
Tire wear indicator bars are visible on the tread surfaces.
•
Tire cords or fabric are visible through cracked sidewalls,
snags or deep cuts.
•
A bump, bulge or split in the tire.
•
Puncture, cut or other damage to the tire that cannot be
repaired.
1
2
sm02177b
1. Sidewall
2. Tread surface
Figure 2-30. Tread Wear Indicators (Typical)
REMOVAL
NOTE
Care must be taken when removing and installing tire to prevent
cosmetic damage to wheel. This is especially true with wheels
that feature painted surfaces.
1.
Remove wheel from motorcycle:
a.
Front wheel:
see
b.
Rear wheel:
see
.
2.
Deflate tire.
NOTE
On tube type wheels, it is not necessary to completely remove
tire from rim to replace tube. Removing one side allows the
tube to be replaced and allows for inspection of tire.
3.
Loosen both tire beads from rim flange. In most cases, a
bead breaker machine will be required to loosen the beads
from the rim.
4.
Remove tire.
CLEANING, INSPECTION AND REPAIR
1.
Clean the inside of tire and outer surface of tube.
2013 Softail Service: Chassis 2-29
2.
If rim is dirty or rusty, clean with a stiff wire brush.
3.
Check wheels for lateral and radial runout before installing
a tire. See
2.7 CHECKING AND TRUING WHEELS
4.
Inspect the tire for wear and damage.
5.
Inspect tread depth. Replace worn tires.
6.
Replace tube and rim seal prior to installing tire.
Replace punctured or damaged tires. In some cases, small
punctures in the tread area may be repaired from within
the removed tire by a Harley-Davidson dealer. Speed
should NOT exceed 50 mph (80 km/h) for the first 24 hours
after repair, and the repaired tire should NEVER be used
over 80 mph (130 km/h). Failure to follow this warning
could lead to tire failure and result in death or serious
injury. (00015b)
7.
Repair tread on tubeless tires if puncture is 1/4 in (6.4 mm)
or smaller. Repairs must be made from inside the tire.
8.
Always combine a patch and plug when repairing damaged
tires.
INSTALLATION
TORQUE VALUE
FASTENER
1.4-1.7 Nm
12-15
in-lbs
Valve stem nut
1.4-1.7 Nm
12-15
in-lbs
Valve stem nut
Harley-Davidson front and rear tires are not the same.
Interchanging front and rear tires can cause tire failure,
which could result in death or serious injury. (00026a)
Do not exceed manufacturer's recommended pressure to
seat beads. Exceeding recommended bead seat pressure
can cause tire rim assembly to burst, which could result
in death or serious injury. (00282a)
Be sure tires are properly inflated, balanced, undamaged,
and have adequate tread. Inspect your tires regularly and
see a Harley-Davidson dealer for replacements. Riding
with excessively worn, unbalanced, improperly inflated,
overloaded or damaged tires can lead to tire failure and
adversely affect stability and handling, which could result
in death or serious injury. (00014b)
For tire pressures, see
.
Some tires have arrows molded into the tire sidewall. Mount
these tires with the arrow pointing in the direction of forward
rotation. The colored dot on the sidewall is a balance mark.
Located it aligned with the valve stem.
Tube Type Tires
Match tires, tubes, rim strips or seals, air valves and caps
to the correct wheel. Contact a Harley-Davidson dealer.
Mismatching can lead to tire damage, allow tire slippage
on the wheel or cause tire failure, which could result in
death or serious injury. (00023c)
NOTES
•
For correct tire and tube types, see
•
Whenever a tube type tire is replaced, the tube should
also be replaced. Inner tubes should be patched only as
an emergency measure. Replace a damaged or patched
tube as soon as possible. Rim bands must be used on all
tube type laced wheels.
1.
See
. On tube type laced wheels, verify that
no spokes protrude through nipples. Install a rim strip into
the rim well. Be sure to align the valve stem hole in rim
strip with valve stem hole in rim.
2.
Install tube and tire.
sm02466
Figure 2-31. Installing Rim Strip
Tubeless Tires: Cast Wheels
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)
2-30 2013 Softail Service: Chassis
On tubeless cast wheels, replace damaged or leaking valve
stems.
1.
See
. Install rubber grommet (5) on valve stem.
2.
Insert valve stem into rim hole.
3.
Install metal washer (4) and nut (3).
4.
Tighten to 12-15
in-lbs
(1.4-1.7 Nm).
5.
Install tire.
4
2
5
3
1
sm07581
1. Bolt-on valve stem
2. Snap-in valve stem
3. Nut
4. Metal washer
5. Rubber grommet
Figure 2-32. Tubeless Tire Valve Stems
Tubeless Tires: Laced Wheels
Do not use lubricants when installing rim seal. Lubricants
can cause rim seal slippage leading to rapid tire deflation,
which could result in death or serious injury. (00612b)
Match tires, tubes, rim strips or seals, air valves and caps
to the correct wheel. Contact a Harley-Davidson dealer.
Mismatching can lead to tire damage, allow tire slippage
on the wheel or cause tire failure, which could result in
death or serious injury. (00023c)
Install new seal before mounting tire. Riding motorcycle
without seal in place can sever valve stem causing rapid
air loss leading to the loss of control, which could result
in death or serious injury. (00622b)
See
.
Tubeless laced (spoked) rims are identified
by the word "TUBELESS" etched into the outside of the
rim and are manufactured to the MTM profile. A typical
identifier would be "TUBELESS 16M/CxMTM3.00 T DOT".
•
Do not install a rim seal and tubeless tire on a laced
rim that is not identified as such.
•
Do not install a tube in a tire mounted on a tubeless
laced rim.
•
Do not install a tire on a tubeless laced rim without
the rim strip and rim seal installed.
Failure to follow these guidelines could result in sudden
and unexpected loss of air pressure, resulting in loss of
control, serious injury, or death.
NOTES
•
On tubeless laced wheels, a damaged or leaking valve
stem requires replacement of the rim seal.
•
Always replace the rim strip and rim seal whenever the
tire is removed.
•
Do not use lubricant when installing rim strip and rim seal.
Use lubricant only when installing tire to rim.
•
Only install original equipment tubeless rim seals and valve
caps.
•
Place rim in a tire mounting fixture to ease rim strip and
seal installation.
1.
See
. Install a
new
rim strip (2) and rim seal
(1).
2.
Insert valve stem through the rim hole and secure with
nut. Tighten to 12-15
in-lbs
(1.4-1.7 Nm).
3.
Install tire.
sm06835a
Figure 2-33. Tubeless Laced Wheel Identification
2013 Softail Service: Chassis 2-31
1
2
3
sm07284
1. Rim seal
2. Rim strip
3. Wheel
Figure 2-34. Tubeless Wheel and Seal
CHECKING TIRE RUNOUT
Lateral Runout
1.
Check tire pressure.
2.
See
. Turn the wheel on the axle and measure
tire lateral runout from a fixed point to a smooth area on
the tire sidewall. Avoid measuring on raised letters or
vents.
3.
Tire lateral runout should not exceed 0.090 in (2.29 mm).
If tire runout exceeds specification, remove tire from rim
and check rim lateral runout. See
a.
If rim lateral runout is within specification, the tire is
at fault and must be replaced.
b.
If rim lateral runout is not within specification, correct
by adjusting selected spokes on laced wheels or
replace cast wheels. See
4.
Install the tire. Check tire lateral runout of replacement
tire.
sm01803
Figure 2-35. Checking Tire Lateral Runout
Radial Runout
1.
Check tire pressure.
2.
See
. Turn the wheel on the axle and measure
tire radial runout at the tread centerline.
3.
Tire radial runout should not exceed 0.090 in (2.29 mm).
If tire runout exceeds this specification, remove tire from
rim and check rim radial runout.See
.
a.
If rim radial runout is within specification, the tire is at
fault and must be replaced.
b.
If rim radial runout is not within specification, correct
by adjusting selected spokes on laced wheels or
replace cast wheels. See
.
4.
Install the tire. Check tire radial runout of replacement tire.
sm01804
Figure 2-36. Checking Tire Radial Runout
2-32 2013 Softail Service: Chassis
WHEEL BALANCING
NOTE
Install tire after balancing. See See
or
.
Static vs Dynamic
Wheel balancing is recommended to improve handling. Balan-
cing wheels reduces vibration especially at high speeds.
Static balancing will produce satisfactory results for normal
highway speeds. Dynamic balancing can produce better results
for deceleration.
Weights
The maximum weight permissible to accomplish balance is 3.5
oz (99.2 g) (total weight applied to the rim). If more than 3.5
oz (99.2 g) of weight is required, rotate the tire 180 degrees
on the rim and again balance the assembly. Balance wheels
to within 0.5 oz (14 g).
All wheel weights currently supplied by Harley-Davidson are
made from zinc which is lighter than lead. The weight of each
zinc segment is 0.18 oz (5 g) as compared to 0.25 oz (7 g) for
lead. Weights are stamped for easy identification.
NOTES
•
If adding more than 1.5 oz (43 g) of weight at one location,
divide the amount so that half is applied to each side of
rim.
•
On cast wheels without a flat area near the bead, place
the weights crosswise through the opening.
1.
See
. Place weights on a smooth surface of
the wheel rim such that centrifugal force will help keep
them in place. Make sure the area of application is com-
pletely clean, dry, and free of oil and grease.
NOTE
See
. When installing wheel weights, consider
cosmetics. Keep snaking (1) within 0.040 in (1.02 mm) (2) of
straight. Also keep the angle alignment of individual segments
(3) within 3 degrees.
2.
Remove paper backing from the weight. Press firmly in
place and hold for ten seconds.
3
2
1
sm07192b
1. Snaking
2. Not to exceed 0.040 in (1.02 mm)
3. Not to exceed 3 degree
Figure 2-37. Weight Segment Alignment
1
2
3
4
sm06487
3.
1.
Cast (typical with flat bead area)
Laced steel
2.
4.
Laced profile
Cast (special with no flat bead area)
Figure 2-38. Wheel Weight Placement
2013 Softail Service: Chassis 2-33
2.10
VEHICLE ALIGNMENT
AXLE ALIGNMENT
TOOL NAME
PART NUMBER
AXLE ALIGNMENT PLUGS
HD-48856-A
TORQUE VALUE
FASTENER
129-142 Nm
95-105 ft-lbs
Axle nut, rear
Checking Axle Alignment
Only a Harley-Davidson dealer should perform vehicle
alignment. Improper alignment can adversely affect sta-
bility and handling, which could result in death or serious
injury. (00060a)
Check vehicle alignment according to following proced-
ures. Incorrect alignment can adversely affect stability and
handling, which could result in death or serious injury.
(00287a)
1.
Verify
wheels
are
true
to
specifications.
See
2.7 CHECKING AND TRUING WHEELS
2.
Check steering head bearing adjustment and adjust if
necessary. See
3.
Remove exhaust components as necessary.
4.
See
. Insert alignment plugs (1, 2) from the
AXLE ALIGNMENT PLUGS (Part No. HD-48856-A) into
left and right ends of rear axle. Turn handle until plug is
firmly held in the axle.
5.
See
. Fabricate an alignment tool using a piece
of 1/8 in (3.175 mm) diameter aluminum welding rod
approximately 20 in (508 mm) long:
a.
Grind one end down to a blunt point (1).
b.
Use pliers to bend rod at a 90 degree angle (3), 1.75
in (44.45 mm) from the blunt point.
c.
Place a snug-fitting rubber grommet (2) on rod to act
as a slide measurement indicator.
6.
Gauge distance between rear fork pivot bolt and rear axle
alignment plug center:
a.
See
. Measure outer diameter of rear fork
pivot bolt and divide measurement by two. Using a
pencil, draw a line from two different directions to
mark an X.
b.
See
. Place blunt point of alignment tool
(1) in the center of the X marked on the rear fork pivot
bolt (2).
c.
Slide rubber grommet (3) along tool shaft until it aligns
with hole in center of alignment plug (4).
d.
Without moving grommet, position alignment tool on
left side of rear fork.
7.
Check measurements on both sides of vehicle. Left and
right measurements must be equal within 0.03125 in.
(0.79375 mm) on both sides of vehicle. Adjust if necessary.
See Adjusting Axle Alignment below.
1
2
3
sm03937
1. Alignment plug (left side)
2. Alignment plug (right side)
3. Alignment hole
Figure 2-39. Axle Alignment Plugs
1
2
3
4
sm05426
1. Blunt point
2. Rubber grommet
3. 1.75 in (44.45 mm)
4. 18 in (457 mm)
Figure 2-40. Axle Alignment Tool
2-34 2013 Softail Service: Chassis
sm07509
Figure 2-41. Pivot Bolt Center Marking
1
4
3
2
sm07498
1. Axle alignment tool
2. Rear fork pivot bolt (marked with X)
3. Rubber grommet
4. Axle alignment plug
Figure 2-42. Checking Alignment Using Axle Alignment
Tool
Adjusting Axle Alignment
1.
All but FXSB:
See
. Remove e-clip (1). Loosen
rear axle nut (2).
2.
FXSB:
See
. Loosen rear axle nut (2).
3.
On side of rear fork that has longer distance from pivot
bolt to axle center, turn nut on axle adjuster (3) counter-
clockwise to shorten distance. Adjust axle until left and
right side alignment measurements are equal.
NOTES
•
Keep axle adjuster mechanisms firmly seated (under ten-
sion) on each side of rear fork during wheel alignment
procedures above. Do so by applying moderate upward
force on lower span of drive belt. This tensions drive belt,
which holds rear axle forward against both adjuster
mechanisms.
•
Do not tighten rear axle nut or install new E-clip until after
checking drive belt deflection.
4.
Verify drive belt deflection after aligning rear wheel. Adjust
if required. See
1.12 DRIVE BELT AND SPROCKETS,
Do not exceed specified torque when tightening axle nut.
Exceeding torque can cause wheel bearings to seize during
vehicle operation, which could result in death or serious
injury. (00408e)
5.
Tighten axle nut to 95-105 ft-lbs (129-142 Nm).
6.
All but FXSB:
See
. Install e-clip.
7.
Erase pencil marks on pivot shaft when complete.
8.
Install exhaust components.
1
2
3
sm02594a
1. E-Clip
2. Axle nut
3. Axle adjuster
Figure 2-43. Axle Adjusters
1
3
2
smo3882
1. Retainer
2. Axle nut
3. Axle adjuster
Figure 2-44. Axle Adjusters: FXSB
2013 Softail Service: Chassis 2-35
2.11
FRONT BRAKE MASTER CYLINDER
GENERAL
Do not use parts from single caliper repair kits (9/16 inch
bore) on dual caliper models. Likewise, do not use parts
from dual caliper repair kits (11/16 inch bore) on single
caliper models. Using incorrect parts can cause brake
failure, which could result in death or serious injury.
(00278a)
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
Do not allow dirt or debris to enter the master cylinder
reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)
See
. Master cylinders designed for dual disc (two
caliper) operation have an 11/16 in. (17.5 mm) bore, while
those that are designed for single disc (one caliper) operation
have a 9/16 in. (14.3 mm) bore. The bore size is stamped on
the master cylinder assembly inboard of the handlebar clamp
bracket.
REMOVAL AND DISASSEMBLY
1.
Drain brake fluid.
a.
Open bleeder nipple cap on front brake caliper.
b.
Install end of a length of clear plastic tubing over cal-
iper bleeder valve, while placing free end in a suitable
container.
c.
Open bleeder valve about 1/2-turn.
d.
Pump brake hand lever to drain brake fluid.
e.
Close bleeder valve.
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and master cylinder bore are clean and undamaged before
assembly. (00322a)
2.
Remove bolt and two steel/rubber washers to disconnect
fitting of hydraulic brake line from master cylinder. Discard
washers.
2-36 2013 Softail Service: Chassis
18
17
16
15
14
8
9
13
12
11
10
7
6
5
4
3
1
2
22
19
20
21
sm03169
12.
1.
Site glass
Lubricant
2.
13.
Wiper
Screw (2)
14.
3.
Master cylinder reservoir
Piston cap
4.
15.
O-ring
Pivot pin
16.
5.
Bushing
Piston
6.
17.
Primary cup
Brake hand lever
18.
7.
Retaining ring
Spring
8.
19.
Handlebar clamp
Flat side
20.
9.
Shoulder
TORX screw and washer (2)
10.
21.
Gasket
Pin
22.
11.
O-ring groove
Cover
Figure 2-45. Front Brake Master Cylinder
3.
See
. Loosen both switch housing clamp
screws. Remove the two T27 TORX screws with flat
washers (9) to detach the handlebar clamp (8) from the
master cylinder reservoir (14).
4.
Remove retaining ring (18) from pivot pin groove at bottom
of master cylinder bracket.
5.
Remove pivot pin (15) and brake hand lever (17).
6.
Carefully remove wiper (2) with pick or similar tool.
7.
Remove piston cap (3).
8.
Remove piston (5) with O-ring (4) and primary cup (6).
9.
Remove spring (7).
2013 Softail Service: Chassis 2-37
10. Remove both screws (13), cover (11) and the cover gasket
(10).
CLEANING AND INSPECTION
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.
Clean all parts with denatured alcohol or DOT 4 BRAKE
FLUID.
a.
Wipe dry with a clean, lint-free cloth.
b.
Clear drilled passages and bore with clean com-
pressed air.
NOTE
Do not use a wire or similar instrument to clean drilled passages
in bottom of reservoir.
2.
Carefully inspect all parts for wear or damage. Replace
as necessary.
3.
Inspect the piston bore in the master cylinder housing for
scoring, pitting or corrosion. Replace as necessary.
4.
Carefully inspect the outlet port that mates with the brake
line fitting. As a critical sealing surface, replace the housing
if any damage is noted.
5.
Carefully inspect the cover gasket for damage. Replace
as necessary.
ASSEMBLY AND INSTALLATION
TORQUE VALUE
FASTENER
6.8-9.0 Nm
60-80
in-lbs
Handlebar switch clamp screw
4.0-5.1 Nm
35-45
in-lbs
Handlebar switch housing
screw
23.1-29.9 Nm
17-22 ft-lbs
Brake caliper/master cylinder
banjo bolt
NOTE
Always reassemble the master cylinder using new parts from
the correct repair kit.
1.
See
. Install O-ring (4) into groove on outboard
side of piston (5) (pin side).
2.
Install primary cup (6) over lip on inboard side of piston
with closed side (smaller OD) contacting shoulder.
3.
Coat piston bore of master cylinder reservoir with special
lubricant (1) supplied in the service parts kit. Also apply
the lubricant to OD of installed O-ring (4) and primary cup
(6).
4.
Insert spring (7) into piston bore, seated against counter-
bore (recess) at bottom.
5.
Slide piston over spring.
6.
Install wiper (2) over piston cap (3) with flat side of wiper
contacting cap shoulder.
7.
Fit piston cap over piston pin (5).
8.
Press down on wiper until it contacts the counterbore.
Larger OD of wiper must be completely seated in groove
on outlet side of piston bore.
9.
Install the master cylinder reservoir cover (11). Secure
with two screws, but do not tighten at this time.
10. Assemble brake hand lever (17) to master cylinder bracket.
From the top of the assembly, install pivot pin (15) through
bracket and hand lever.
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
11. Install
new
retaining ring (18) in pivot pin groove. Verify
that retaining ring is completely seated in groove.
12. See
. Position the brake lever/master cylinder
assembly inboard of the switch housing assembly, enga-
ging the tab (2) on the lower switch housing (1) in the
groove (3) at the top of the brake lever bracket (4).
13. Secure the handlebar clamp to master cylinder with two
screws (with flat washers). Position hand lever and controls
for rider comfort. Beginning with the top screw, tighten to
60-80
in-lbs
(6.8-9.0 Nm).
14. Tighten switch housing screws to 35-45
in-lbs
(4.0-5.1
Nm).
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and caliper bore are clean and undamaged before
assembly. (00321a)
15. Start banjo bolt (with
new
steel/rubber washers) to secure
brake line fitting to master cylinder reservoir. Tighten banjo
bolt to 17-22 ft-lbs (23.1-29.9 Nm).
When any hydraulic brake component, line or connection
is loosened or replaced on an ABS motorcycle, Digital
Technician II must be used during the brake bleeding
procedure to verify all air is removed from the system.
Failure to properly bleed the brake system could adversely
affect braking, which could result in death or serious injury.
(00585c)
16. Bleed front brake system. See
2-38 2013 Softail Service: Chassis
NOTE
The shelf life of an unopened bottle of DOT 4 brake fluid is one
year. The shelf life of an uncontaminated bottle that has been
opened and then resealed is one week.
4
3
2
1
sm07078
1. Switch housing assembly
2. Tab
3. Groove
4. Brake lever bracket
Figure 2-46. Attach Master Cylinder to Right Handlebar
Switches
2013 Softail Service: Chassis 2-39
2.12
FRONT BRAKE CALIPER
REMOVAL
NOTE
If only replacing brake pads, 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)
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and caliper bore are clean and undamaged before
assembly. (00321a)
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)
1.
See
. Remove the banjo bolt (1) and both
steel/rubber washers (2) to detach front brake line (3) from
caliper. Discard washers.
2.
Remove the upper (4) and lower (5) mounting bolts
(metric). Lift caliper upward to remove from brake disc.
1
2
4
3
5
sm04090b
1. Banjo bolt
2. Steel/rubber washer (2)
3. Front brake line
4. Upper mounting bolt (metric)
5. Lower mounting bolt (metric)
Figure 2-47. Front Caliper
DISASSEMBLY
TOOL NAME
PART NUMBER
FRONT BRAKE CALIPER PISTON
REMOVER
HD-48649
1.
See
. Remove bridge bolt/pad pin (12) (metric),
brake pads (7) and bridge bolt (11) (metric) to separate
caliper housings (1, 8).
2-40 2013 Softail Service: Chassis
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