Harley Davidson 2005 touring models. Service repair manual — page 5
HOME
15. Position new steel/rubber washers on each side of
f1225x2x
hydraulic brake line fitting. Insert banjo bolt through
washers and fitting. Thread bolt into master cylinder
housing and tighten to 17-22 ft-lbs (23-30 Nm).
16. Remove the master cylinder reservoir cover. Stand the
Groove
motorcycle upright so that the master cylinder is in a
level position.
1WARNING
Never mix DOT 4 with other brake fluids (such as DOT 5).
Mixing different types of fluid may adversely affect brak-
ing ability and lead to brake failure which could result in
death or serious injury.
5/32 Inch
(4.0 mm)
Cardboard
Insert
1WARNING
Use only fresh, uncontaminated DOT 4 brake fluid. Fluid
containers that have been opened may have been con-
taminated by dirt or moisture. Use of contaminated
brake fluid may adversely affect braking ability and lead
to brake failure which could result in death or serious
Figure 2-44. Install Cardboard Insert
injury.
Before Installing Master Cylinder Assembly
17. Add DOT 4 BRAKE FLUID to the master cylinder reser-
voir until the fluid level is 1/8 inch (3.2 mm) from the top.
11.
Install new retaining ring in pivot pin groove. Verify that
Do not reuse old brake fluid. Use only DOT 4 fluid from a
retaining ring is completely seated in groove.
sealed container.
CAUTION
1
WARNING
See Figure 2-44. Do not install the master cylinder
A plugged or covered relief port can cause brake drag or
assembly without first placing the 5/32 inch (4.0 mm)
wheel lockup and may lead to loss of vehicle control,
cardboard insert between the brake lever and lever
which could result in death or serious injury.
bracket. Installation without the insert may result in dam-
age to the rubber boot and plunger of the Front Stoplight
Switch.
12. Place the cardboard insert between the brake lever and
f1785x8x
lever bracket. Use the eyelet of an ordinary cable strap if
Brake
Lever
the cardboard insert is not available.
Bracket
Tab
13. Position the brake lever/master cylinder assembly
inboard of the switch housing assembly engaging the
Groove
tab on the lower switch housing in the groove at the top
of the brake lever bracket. See Figure 2-45.
14. Align the holes in the handlebar clamp with those in the
master cylinder housing and start the two screws (with
flat washers). Position for rider comfort. Beginning with
the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0
Nm) torque using a T27 TORX drive head.
Switch
Housing
CAUTION
Assembly
To avoid leakage, verify that the steel/rubber washers,
banjo bolt, brake line fitting and master cylinder bore are
Figure 2-45. Fit Brake Lever/Master Cylinder to
completely clean.
Right Handlebar Switch Housings
2-36
2005 Touring: Chassis
HOME
18. Verify proper operation of the master cylinder relief port.
25. Install cover (with gasket) on the master cylinder reser-
Actuate the brake hand lever. A slight spurt of fluid will
voir, so that the thicker side is positioned above the
break the fluid surface in the reservoir compartment if all
brake line fitting. Install two Phillips screws to fasten the
internal components are working properly.
cover to the reservoir. Tighten the screws to 6-8 in-lbs
(0.7-0.9 Nm).
19. Remove cap from bleeder valve on front brake caliper.
Install end of a length of clear plastic tubing over caliper
26. With the Ignition/Light Key Switch turned to IGNITION,
bleeder valve, while placing free end in a suitable con-
actuate the front brake hand lever to verify operation of
tainer.
the brake lamp.
20. Depress and hold the brake hand lever to build up
hydraulic pressure.
1WARNING
21. Open bleeder valve about 1/2-turn. Brake fluid will flow
After completing repairs or bleeding the system, always
from bleeder valve through tubing. Close bleeder valve
test motorcycle brakes at low speed. If brakes are not
when brake hand lever has moved 1/2 to 3/4 of its full
operating properly or braking efficiency is poor, testing
range of travel. Allow brake hand lever to return slowly to
at high speeds could result in death or serious injury.
its released position.
27. Test ride the motorcycle. If the brake feels spongy,
22. Add brake fluid to the master cylinder reservoir until the
repeat the bleeding procedure.
fluid level is about 1/8 inch (3.2 mm) from the top.
NOTE
23. Repeat steps 20-22 until all air bubbles are purged.
A sight glass enables the rider to visually check the brake
24. Final tighten the bleeder valve to
80-100 in-lbs
fluid level without removing the master cylinder cover. When
(9.0-11.3 Nm). Install the bleeder valve cap.
the reservoir is full, the sight glass is dark. As the fluid level
drops, the glass lightens up to indicate this condition to the
rider.
2005 Touring: Chassis
2-37
HOME
REAR BRAKE MASTER CYLINDER
2.11
5.
Remove bleeder valve cap on rear brake caliper. Install
REMOVAL
end of a length of clear plastic tubing over caliper
bleeder valve, while placing free end in a suitable con-
tainer. Open bleeder valve about 1/2-turn. Pump brake
PRELIMINARY INSTRUCTIONS
pedal to drain brake fluid. Close bleeder valve.
1.
Remove right fairing lower, if present. See Section 2.28
LOWER FAIRING/ENGINE GUARD, LOWER FAIRING
(FLHTCU), REMOVAL.
BRAKE PEDAL/MASTER CYLINDER
2.
Remove two allen head socket screws (with lock wash-
ASSEMBLY, REMOVAL
ers and flat washers) to release right side front footboard
brackets from frame weldment. For best results,
1.
See PRELIMINARY INSTRUCTIONS on this page.
approach from left side of vehicle using a 3/8 inch ball
allen with extension.
2.
Remove banjo bolt and two steel/rubber washers to dis-
connect brake line front fitting from master cylinder
3.
Remove right side saddlebag. See Section 2.25 SAD-
assembly. Discard washers.
DLEBAG, REMOVAL.
4.
Gently pull side cover from frame downtube (no tools
3.
Release rear brake line as needed to move front fitting
required).
forward far enough to access hex nut. For further
instructions See REAR BRAKE LINE, REMOVAL, steps
3-6, in this section.
CAUTION
4.
Using 1-1/8 inch wrench, remove hex nut to free brake
Cover adjacent surfaces when removing, draining, filling
pedal/master cylinder assembly from mounting bracket.
and/or bleeding brake system components. Spilling DOT
4 brake fluid on painted or other finished surfaces can
5.
Remove locknut with flat washer to free brake pedal/
result in cosmetic damage. Immediately wipe up any
master cylinder assembly from pedal shaft. Remove
spilled brake fluid and thoroughly clean affected area
assembly from vehicle. Remove and discard O-ring on
with water or 50/50 mix of water and denatured alcohol.
each side of brake pedal shaft bore. See Figure 2-46.
f2053x2x
O-Ring
Clevis Pin
Rear
Brake Pedal
Flat
Washer
Cotter Pin
Master Cylinder
Reservoir
Retaining
Ring
Figure 2-46. Rear Brake Pedal/Master Cylinder Assembly
2-38
2005 Touring: Chassis
HOME
P-Clamp
Brake Line
and Screw
Hose
Swingarm Bracket
Rear Brake
Steel/Rubber
Brake Hose
Light Switch
Washers
Crimp
Cable Clips
Locating Tab
Top of Rear Swingarm
Brake Line
Tube
Screw and
Weld Nut
Banjo
Frame Weldment
Bolt
Cable Clips
Lower Frame Tube
f1460x2x
Figure 2-47. Rear Brake Line Assembly
6. Remove cotter pin and flat washer from clevis pin. Sup-
5.
Apply Loctite Medium Strength Threadlocker 243 (blue)
porting rear brake pedal/master cylinder assembly in
to threads of hex nut. Install hex nut on threaded end of
vise, tap out clevis pin using a brass drift. Remove mas-
cartridge body and tighten to 30-40 ft-lbs (41-54 Nm).
ter cylinder assembly from brake pedal flange.
6.
Position new steel/rubber washers on each side of brake
7. For further instructions, see MASTER CYLINDER, DIS-
line fitting. Insert banjo bolt through washers and fitting.
ASSEMBLY, in this section.
Thread bolt into master cylinder assembly and tighten to
17-22 ft-lbs (23-30 Nm).
7.
Secure rear brake line if released during master cylinder
BRAKE PEDAL/MASTER CYLINDER
removal. For further instructions, see REAR BRAKE
LINE, INSTALLATION, steps 4-7, in this section.
ASSEMBLY, INSTALLATION
8.
See FINAL INSTRUCTIONS on the next page.
1. If master cylinder was disassembled, see MASTER
CYLINDER, ASSEMBLY, in this section, for instructions.
REAR BRAKE LINE, REMOVAL
2. Install master cylinder assembly on brake pedal flange.
Supporting assembly in vise, tap in clevis pin using a
1.
See PRELIMINARY INSTRUCTIONS on the previous
brass drift. Install flat washer and cotter pin on clevis pin.
page.
See Figure 2-46.
2.
Remove banjo bolt and two steel/rubber washers to dis-
3. Install new O-ring on each side of brake pedal shaft
connect brake line front fitting from master cylinder
bore.
assembly. Discard washers. See Figure 2-47.
3.
Open two cable clips on lower frame tube T-studs. Free
4. Apply a light coat of Wheel Bearing Grease (Part No.
99855-89) to the brake pedal shaft and bore. Install
rear brake line from cable clips.
brake pedal/master cylinder assembly on the pedal shaft
NOTE
fitting collar on cartridge body into square-shaped hole
in mounting bracket. Install flat washer and new locknut
For best results, insert blade of small screwdriver into gap at
on pedal shaft and tighten to 15-20 ft-lbs (20-27 Nm).
side of clip and gently rotate end of screwdriver to pop open.
2005 Touring: Chassis
2-39
HOME
4.
Remove hex screw to free brake hose P-clamp from rear
8. Position new steel/rubber washers on each side of brake
swingarm bracket (passenger footboard bracket).
line front fitting. Insert banjo bolt through washers and
fitting. Thread bolt into master cylinder assembly and
5.
Remove socket terminals from rear brake light switch
tighten to 17-22 ft-lbs (23-30 Nm).
spade contacts. Cut cable strap to free rear brake light
switch wires from lower frame tube, if necessary.
9. See FINAL INSTRUCTIONS on this page.
6.
Remove hex screw to free brake light switch bracket
from frame weldment. Push on bracket to release locat-
ing tab from slot in frame weldment.
7.
Open two cable clips on rear swingarm T-studs. Free
INSTALLATION
rear brake line hose from cable clips.
NOTE
FINAL INSTRUCTIONS
For best results, insert blade of small screwdriver into gap at
side of clip and gently rotate end of screwdriver to pop open.
1.
Insert two allen head socket screws (with lockwashers
and flat washers) through frame weldment into right side
8.
Remove banjo bolt and two steel/rubber washers to dis-
front footboard brackets. For best results, approach from
connect brake line fitting from rear brake caliper. Discard
left side of vehicle using a 3/8 inch ball allen with exten-
washers.
sion. Alternately tighten socket screws to 30-35 ft-lbs
9.
Feed rear brake line hose forward to area in front of rear
(41-48 Nm).
swingarm bracket. Remove rear brake line assembly
2.
Install length of clear plastic tubing over caliper bleeder
from vehicle.
valve, if removed. Place free end of tube in a suitable
container.
3.
Remove the master cylinder cover, if installed. Stand the
REAR BRAKE LINE, INSTALLATION
motorcycle upright so that the master cylinder is in a
1.
Place rear brake line into approximate position along top
level position.
of lower right frame tube. From area in front of rear swin-
garm bracket, feed brake line hose rearward following
1WARNING
top of rear swingarm.
Never mix DOT 4 with other brake fluids (such as DOT 5).
2.
Position new steel/rubber washers on each side of brake
Mixing different types of fluid may adversely affect brak-
line rear fitting. Insert banjo bolt through washers and fit-
ing ability and lead to brake failure which could result in
ting. Thread bolt into rear brake caliper and tighten to
death or serious injury.
17-22 ft-lbs (23-30 Nm).
3.
Capture rear brake line hose in two cable clips on rear
swingarm T-studs. Snap cable clips closed. See Figure
1WARNING
2-48.
Use only fresh, uncontaminated DOT 4 brake fluid. Fluid
4.
Index locating tab on brake light switch bracket in slot of
containers that have been opened may have been con-
frame weldment. Install hex screw to secure brake light
taminated by dirt or moisture. Use of contaminated
switch bracket to frame weldment.
brake fluid may adversely affect braking ability and lead
5.
Install socket terminals onto rear brake light switch
to brake failure which could result in death or serious
spade contacts. If removed, install new cable strap to
injury.
secure rear brake light switch wires to lower frame tube.
6.
Install hex screw to secure brake hose P-clamp to rear
CAUTION
swingarm bracket (passenger footboard bracket).
Cover adjacent surfaces when removing, draining, filling
7.
Capture rear brake line in two cable clips on lower frame
and/or bleeding brake system components. Spilling DOT
tube T-studs. Snap cable clips closed.
4 brake fluid on painted or other finished surfaces can
result in cosmetic damage. Immediately wipe up any
NOTE
spilled brake fluid and thoroughly clean affected area
Rear cable clip also captures main harness conduit to volt-
with water or 50/50 mix of water and denatured alcohol.
age regulator connector and conduit to oil pressure sender
and crankshaft position sensor connectors. Front cable clip
4.
Add DOT 4 BRAKE FLUID to the master cylinder reser-
also captures main harness conduit to oil pressure sender
voir until the fluid level is 1/8 inch (3.2 mm) from the top.
and crankshaft position sensor connectors as well as voltage
Do not reuse old brake fluid. Use only DOT 4 fluid from a
regulator cables.
sealed container.
2-40
2005 Touring: Chassis
HOME
f2316x2x
3rd
Cable Clip
4th
Cable Clip
2nd
Cable Clip
1st
Cable Clip
Rear
Swingarm
Frame
Weldment
Cable Strap
Captures Rear Brake Light Switch Wires
and Lower Frame Tube Only
Figure 2-48. Rear Brake Line Routing (Right Side View)
5.
Depress and hold the rear brake pedal to build up
13. Align barbed studs in side cover with grommets in frame
hydraulic pressure.
downtubes and push firmly into place
(no tools
required).
6.
Open bleeder valve about 1/2-turn. Brake fluid will flow
from bleeder valve through tubing. Close bleeder valve
14. Install right side saddlebag. See Section 2.25 SADDLE-
when rear brake pedal has moved 1/2 to 3/4 of its full
BAG, INSTALLATION.
range of travel. Allow rear brake pedal to return slowly to
its released position.
1WARNING
7.
Repeat steps 4-6 until all air bubbles are purged.
After completing repairs or bleeding the system, always
test motorcycle brakes at low speed. If brakes are not
8.
Final tighten the bleeder valve to
80-100 in-lbs
operating properly or braking efficiency is poor, testing
(9.0-11.3 Nm). Install the bleeder cap.
at high speeds could result in death or serious injury.
9.
Add brake fluid to the master cylinder reservoir until the
fluid level is about 1/8 inch (3.2 mm) from the top.
15. Test ride the motorcycle. If the brake feels spongy,
repeat the bleeding procedure.
10.
Install the cover (with gasket) on the master cylinder res-
ervoir. Install two Phillips screws to fasten the cover to
NOTE
the reservoir. Tighten the screws to 6-8 in-lbs (0.7-0.9
A sight glass enables the rider to visually check the brake
Nm).
fluid level without removing the master cylinder cover. The
11.
With the Ignition/Light Key Switch turned to IGNITION,
sight glass is dark when the reservoir is full, but as the fluid
actuate the rear brake pedal to verify operation of the
level drops, the glass lightens to alert the rider of this condi-
brake lamp.
tion.
12.
Install right fairing lower, if present. See Section 2.28
LOWER FAIRING/ENGINE GUARD, LOWER FAIRING
(FLHTCU), INSTALLATION.
2005 Touring: Chassis
2-41
HOME
NOTE
The push rod, clevis and spacer washer are a one-piece
Clevis
assembly.
5. Remove the large flat washer, dust boot and spring from
the cartridge body. Remove spring and spring retainer
from dust boot.
6. Push on threaded end of cartridge body to remove from
reservoir adapter. Use hand pressure only. Exercise
caution to keep cartridge body free of dirt and grease.
See Figure 2-50.
7. Carefully remove two O-rings from cartridge body. Exer-
cise caution to avoid scratching O-ring grooves.
8. Remove small retaining ring from groove in cartridge
body bore. Piston assembly is spring loaded so be sure
to hold parts together as retaining ring is removed.
Shop
f2050x2x
Cloth
9. Remove push rod with captured spacer washer from
cartridge body. Remove small retaining ring from push
Figure 2-49. Compress Spring and Remove
rod, if attached. Discard retaining ring.
Retaining Ring
NOTE
MASTER CYLINDER
Do not disassemble the cartridge body. The cartridge body
components are not sold separately. If piston seal leakage is
evident, replace the entire cartridge body assembly.
DISASSEMBLY
NOTE
If installing the Master Cylinder Reservoir Kit
(Part
No.
Reservoir
f2054x2x
42454-99), see steps 1-7 below. If installing the Push Rod Kit
Adapter
(Part No. 41957-97A) or the assembled cartridge body from
the Master Cylinder Repair Kit (Part No. 42382-87C), see
steps 1-9.
1. See BRAKE PEDAL/MASTER CYLINDER ASSEMBLY,
REMOVAL, in this section.
2. Thoroughly clean exterior of master cylinder assembly
with denatured alcohol.
3. Stand master cylinder assembly upright on banjo sealing
surface. For best results, suspend reservoir over edge of
table. Be sure to lay down a clean shop cloth to protect
the sealing surface from damage.
1WARNING
Always wear proper eye protection when removing re-
taining rings. Use the correct retaining ring pliers. Verify
that the tips of the pliers are not damaged or excessively
worn. Slippage may propel the ring with enough force to
Cartridge
cause eye injury.
Body
4. Push down on large flat washer to compress spring.
While holding the spring in a compressed state, remove
Figure 2-50. Remove Cartridge From Reservoir Adapter
retaining ring from groove in clevis and then carefully
release spring. See Figure 2-49. Discard retaining ring.
2-42
2005 Touring: Chassis
HOME
18
f2100x2x
1. Hex Nut
19
2. Reservoir
17
3. O-Ring
14
4. Cartridge Body
5. Spring
13
6. Primary Cup
7. Piston
16
12
8. O-Ring
15
9. Push Rod/Clevis/Spacer Washer*
11
10. Retaining Ring
11. Retaining Ring
10
12. Spring
13. Spring Retainer
9
8
7
Banjo
6
Sealing Surface
14. Dust Boot
5
15. Washer
16. Retaining Ring
3
17. Clevis Pin
18. Flat Washer
4
19. Cotter Pin
3
1
2
*Push rod, clevis and spacer washer are a one-piece assembly
Figure 2-51. Rear Brake Master Cylinder Assembly (Exploded View)
CLEANING AND INSPECTION
3.
Check the dust boot for cuts or tears. Replace as neces-
sary.
4.
Inspect the threads on the cartridge body. Replace if
1WARNING
threads are damaged.
Use denatured alcohol to clean brake system compo-
5.
Inspect the spring for distortion, cracks or broken coils.
nents. Do not use mineral base solvents (such as gaso-
Replace as necessary.
line and paint thinner) or deterioration of rubber parts
may occur after assembly. Deterioration of components
6.
Inspect O-ring grooves on the cartridge body for dirt.
may result in premature brake failure, which could result
Carefully clean grooves using a soft cotton cloth moist-
in death or serious injury.
ened with alcohol and allow to dry. Inspect O-ring
grooves for scratches. Replace cartridge body if grooves
1.
Clean all metal parts, except the cartridge body assem-
are scratched.
bly, and blow dry with compressed air. Clean all rubber
parts using denatured alcohol.
7.
Inspect the reservoir cover gasket for cuts, tears or gen-
2.
Inspect the reservoir adapter bore for scratches.
eral deterioration. If gasket and/or sight glass replace-
Replace the reservoir if scratches are present.
ment is necessary, proceed as follows:
2005 Touring: Chassis
2-43
HOME
a. From inboard side, push sight glass toward top of
cover until free.
b. Pull rubber gasket from cover.
c. Fit nipple of new gasket into hole of cover aligning
gasket and cover thru holes.
Retaining
d. From bottom of gasket, push flat end of sight glass
Ring
Push Rod
through nipple until top of glass is flush with top of
gasket. Verify that glass is square in bore. If some
lubrication is necessary, use a small quantity of
Cartridge
clean brake fluid.
Body
ASSEMBLY
NOTE
If installing assembled cartridge body from Master Cylinder
Repair Kit (Part No. 42382-87C), begin at step 2 below. If
installing the Push Rod Kit (Part No. 41957-97A), begin at
Shop
step 3. If installing the Master Cylinder Reservoir Kit (Part
f2049x2x
Cloth
No. 42454-99), start at step 7.
Figure 2-52. Compress Spring and Install Retaining Ring
1. To install piston in cartridge body, proceed as follows:
a. Install small spring into cartridge body making sure
Dust
that spring is seated in counterbore.
Spring
Boot
Retainer
b. Lightly lubricate primary cup and O-ring on piston
with DOT 4 BRAKE FLUID.
c. Install piston over spring.
2. Install new large retaining ring in groove on push rod
side of cartridge body.
3. Position new retaining ring on push rod between spacer
Spring
washer and clevis, or on clevis inboard of the retaining
ring groove.
NOTE
The push rod, clevis and spacer washer are a one-piece
assembly.
4. Stand cartridge body upright on banjo sealing surface.
Lay down a clean shop cloth to protect the sealing sur-
face from damage. See Figure 2-52.
Reservoir
f2055x2x
1WARNING
Always wear proper eye protection when installing re-
Figure 2-53. Install Spring, Spring Retainer and Dust Boot
taining rings. Use the correct retaining ring pliers. Verify
that the tips of the pliers are not damaged or excessively
worn. Slippage may propel the ring with enough force to
cause eye injury.
6. Verify that retaining ring is completely seated in groove
and that push rod rotates freely.
5. Insert ball end of push rod into piston cup. Pushing down
7. Lubricate new O-rings with DOT 4 BRAKE FLUID and
on push rod to compress spring, fit captured spacer
carefully install in grooves on outside of cartridge body.
washer into cartridge body. Further compressing spring
as necessary, install retaining ring positioned in step 4 in
8. Wipe bore of reservoir adapter with DOT 4 BRAKE
groove of cartridge body bore.
FLUID.
2-44
2005 Touring: Chassis
HOME
f2051x2x
Dust Boot
Retaining
Retaining
Ring
Reservoir
Ring
Adapter
Spacer
O-Ring
Brake Line
Washer*
Flat
Seating Surface
Must Not Be
Washer
Scratched or Dented
Clevis*
During Handling
Mounting
Retaining
1-1/8 Inch Hex Nut
Ring
Primary
Cup
O-Ring
Spring
Cartridge
Piston
Spring
Push Rod*
Body
Drain/Air
Retainer
Spring
Hole At
Bottom
*Push rod, clevis and spacer washer are a one-piece assembly
Figure 2-54. Rear Brake Master Cylinder Assembly (Cross Sectional View)
9. Insert cartridge body into reservoir adapter indexing tab
14. Place large flat washer on top of dust boot fitting inside
on adapter in slot on threaded end of cartridge. Use
tabs in slot of clevis.
hand pressure only. Cartridge body is fully installed
15. Push down on large flat washer to compress spring.
when reservoir adapter contacts large retaining ring.
While holding spring in a compressed state, install new
10. Stand master cylinder assembly upright on banjo sealing
retaining ring in groove of clevis.
surface. For best results, suspend reservoir over edge of
16. Pull down dust boot as necessary to seat over lip on res-
table. Be sure to lay down a clean shop cloth to protect
ervoir adapter.
the sealing surface from damage.
17. Rotate boot so that drain/air hole is at the bottom.
11. Install spring over push rod and cartridge body until it
18. See BRAKE PEDAL/MASTER CYLINDER ASSEMBLY,
contacts side of large retaining ring. See Figure 2-53.
INSTALLATION, in this section.
12. Place concave side of spring retainer over end of spring
fitting inside tabs in slot of clevis.
13. Slide dust boot over spring and spring retainer.
2005 Touring: Chassis
2-45
HOME
FRONT BRAKE CALIPER
2.12
INSPECTION
Caliper
Check brake pads and discs:
● At every scheduled service interval.
● Whenever the components are removed during normal
service procedures.
Right
BRAKE DISC THICKNESS/WARPAGE
Front Brake
Bottom View
The minimum brake disc thickness is stamped on the side of
the disc. Replace disc if excessively worn or badly scored.
Maximum brake disc lateral runout or warpage is 0.008 inch
(0.20 mm) when measured near the outside diameter.
Friction
Backing
Material
Replace disc if warped beyond specification. For replace-
Plate
Outer Pad
ment instructions, see Section 2.3 FRONT WHEEL, DISAS-
SEMBLY.
Brake
Disc
BRAKE PADS
f1756x2x
NOTE
Brake pad inspection can be performed without removing the
Replace both pads if friction material of either pad is
caliper.
0.04 inch (1.02 mm) or less above the backing plate.
1. Look up at the back of the right side caliper. See Figure
Figure 2-55. Measure Brake Pad Wear
2-55.
2. Place a thin plastic 6 inch rule against the brake disc and
measure the friction material of the brake outer pad.
FRONT BRAKE PAD
Using a small hand mirror, visually check the friction
material of the inner pad.
REPLACEMENT
3. Repeat above checks at the front of the right side cali-
per. Replace both pads If the friction material above the
PAD REMOVAL
backing plate on either pad is 0.04 inch (1.02 mm) thick
or less.
1.
Use shop rag or tape to protect fender area adjacent to
4. Repeat steps 1-3 on the left side of the vehicle.
caliper, as incidental contact can occur during caliper
removal.
1WARNING
2.
Loosen two pad pins, but do not remove. See Figure 2-
56.
Always replace brake pads in pairs. Never replace just
one brake pad. Mismatched brake pads can lead to brake
3.
Remove upper and lower caliper mounting bolts from
system damage and loss of braking performance, which
front fork mounting lugs. Lift caliper upward to remove
could result in death or serious injury.
from brake disc.
5. See FRONT BRAKE PAD REPLACEMENT on this
page.
CAUTION
Cover adjacent surfaces when removing, draining, filling
and/or bleeding brake system components. Spilling DOT
BRAKE LINE/HOSE INSPECTION
4 brake fluid on painted or other finished surfaces can
result in cosmetic damage. Immediately wipe up any
When checking brake pads and discs, take the time to
spilled brake fluid and thoroughly clean affected area
inspect the brake lines and hoses for damage or wear.
with water or 50/50 mix of water and denatured alcohol.
Replace as necessary.
2-46
2005 Touring: Chassis
HOME
5.
Pry back inner and outer brake pads pushing the four
Upper Caliper
pistons back into their bores.
Mounting Bolt
(Long)
6.
With the pistons retracted, remove two pad pins and
both inner and outer brake pads. Inspect pad pins. See
Pad
CLEANING AND INSPECTION, step 4.
Pins
NOTE
Replacing one pad at a time keeps the anti-rattle spring in
place. Remove both pads to remove or replace the spring.
PAD INSTALLATION
NOTE
Both front calipers (as well as the rear brake caliper) use the
same brake pad set.
1.
Install new brake pads into caliper with the friction mate-
rial facing the brake disc opening. Be sure that the pad is
Lower Caliper
oriented so that the curved side faces the rear of the
Mounting Bolt
f1767x2x
vehicle when the caliper is installed. See Figure 2-57.
(Short)
Furthermore, note that the backing plate of each brake
Figure 2-56. Loosen Pad Pins and Remove Caliper
pad has either one or two tabs. On the right side of the
Mounting Bolts (Right Side View)
vehicle, the pad with two tabs is installed on the inboard
side of the caliper, the pad with the single tab is installed
on the outboard side.
CAUTION
On the left side of the vehicle, the pad location is
reversed. Therefore, the pad with the single tab is
To prevent dirt and other contaminants from entering the
installed on the inboard side of the caliper, while the pad
master cylinder reservoir, thoroughly clean the cover
with two tabs is installed on the outboard side.
before removal.
2.
Install pad pins, but do not fully tighten at this time.
4. Remove two Phillips screws to release cover from front
master cylinder reservoir.
3.
Install calipers as follows:
a. Use shop rag or tape to protect fender area adja-
NOTE
cent to caliper, as incidental contact can occur dur-
As the pistons are pushed back into the caliper, fluid level
ing caliper installation.
may rise more than 1/8 inch (3.2 mm) and overflow the reser-
voir. Watch the fluid level as the pistons are retracted and
b. Place caliper over brake disc with bleeder valve top-
remove fluid from the reservoir if necessary.
side.
Outboard Side
Inboard Side
Inboard Side
Outboard Side
of Caliper
of Caliper
of Caliper
of Caliper
Two Tabs
Single
Two Tabs
Single
Tab
Tab
Curved Portion
Curved Portion
Faces Rear
Faces Rear
Left Side of Vehicle
f2156x2x
f2156x2x
Right Side of Vehicle
Figure 2-57. Front Brake Pad Locations
2005 Touring: Chassis
2-47
HOME
Per Caliper Assembly
1.
Inside Caliper Housing
2.
Square Seal (4)
14
3.
Wiper (4)
16
4.
Piston (4)
5.
Crossover O-Ring (2)
13
6.
Inner Brake Pad
7.
Outer Brake Pad
15
8.
Anti-Rattle Spring
9.
Outside Caliper Housing
10.
Lower Mounting Bolt (Short)
11
11.
Upper Mounting Bolt (Long)
12
12.
Decal
2
8
13.
Pad Pin (2)
4
14.
Bridge Bolt (2)
15.
Bleeder Valve
10
16.
Bleeder Valve Cap
9
5
3
4
7
6
3
2
f2182x2x
1
Figure 2-58. Front Brake Caliper Assembly (Left Side)
c. Loosely install long caliper mounting bolt into upper
4. Pump brake hand lever until pistons contact brake pads
lug of front fork leg.
and pads contact brake discs. Verify piston location
against pads. If the front wheel is off the ground, rotate
d. Install short caliper mounting bolt into lower lug of
wheel to check for excessive brake pad drag.
front fork leg. Tighten lower mounting bolt to 28-38
5. Verify that brake fluid level is 1/8 inch (3.2 mm) below top
ft-lbs (37.9-51.5 Nm).
of reservoir with master cylinder in a level position. Add
DOT 4 BRAKE FLUID, if necessary.
e. Tighten upper caliper mounting bolt to 28-38 ft-lbs
(37.9-51.5 Nm).
6. Install master cylinder reservoir cover. Install two Phillips
screws to fasten cover to reservoir and tighten to 6-8 in-
f.
Tighten pad pins to 180-200 in-lbs (20.3-22.6 Nm).
lbs (0.7-0.9 Nm).
7. Test operation of brake lamp with the front brake applied
1WARNING
and the Ignition/Light Key Switch turned to IGNITION.
After installation of new pads and BEFORE moving
motorcycle, pump front brake hand lever until pistons
1WARNING
push pads against the brake discs. If fluid pressure is
After completing repairs or bleeding the system, always
not pumped up, the brakes will not be available the first
test motorcycle brakes at low speed. If brakes are not
time they are used, a situation that could result in death
operating properly or braking efficiency is poor, testing
or serious injury.
at high speeds could result in death or serious injury.
2-48
2005 Touring: Chassis
HOME
f1776x2x
Low Pressure
Air Hose
Brake Caliper Piston Remover
(Part No. HD-43293A)
CAUTION
To prevent air from escaping through the banjo
bolt hole, and to avoid scratching or nicking the
Tapered,
banjo seating surface, use only a tapered, rubber
Rubber-Tipped
tipped nozzle on air hose. Loss of air pressure
will keep the pistons from moving, while any
Nozzle
Bridge
Brake Caliper
damage to the banjo seating surface requires
Bolt
Piston Remover
caliper replacement.
Figure 2-59. Direct Compressed Air Into Banjo Bolt Hole to Force Pistons From Bores
8. Test ride the motorcycle. If the brakes feel spongy, bleed
CALIPER DISASSEMBLY
the system. See Section 2.14 BLEEDING HYDRAULIC
BRAKES.
1.
See Figure 2-56. Remove two pad pins. Remove brake
NOTE
pads from caliper housings.
To allow new brake pads to “wear in” properly with the brake
2.
Remove two bridge bolts and separate inside and out-
disc, avoid making hard stops for the first 100 miles (160 km).
side caliper housings.
3.
Remove anti-rattle spring from channel around boss in
outside caliper housing.
CALIPER REMOVAL
4.
Remove bleeder valve, if damaged.
NOTE
1WARNING
If only replacing brake pads, see FRONT BRAKE PAD
REPLACEMENT in this section.
Pressurized air can blow debris into your face and eyes.
Always wear eye protection or a face shield. Failure to do
so could result in eye injury.
CAUTION
Damaged banjo bolt surfaces will leak when reassem-
5.
Remove four pistons as follows:
bled. Prevent damage to seating surfaces by carefully
a. Obtain BRAKE CALIPER PISTON REMOVER (Part
removing brake line components.
No. HD-43293A). See inset of Figure 2-59.
1. Remove banjo bolt and two steel/rubber washers to
b. Seat tool in outside caliper housing aligning outside
detach front brake line from caliper. Discard washers.
holes in tool with bridge bolt holes in housing. Place
2. Use shop rag or tape to protect fender area adjacent to
inside caliper housing over tool aligning bridge bolt
caliper, as incidental contact can occur during caliper
holes with outside holes in tool.
removal.
c. Install bridge bolts and tighten securely.
3. Remove upper and lower caliper mounting bolts from
front fork mounting lugs. Lift caliper upward to remove
d. If the bleeder valve was removed, reinstall finger
from brake disc.
tight or place a gloved finger over the valve hole.
2005 Touring: Chassis
2-49
HOME
1. Clean all parts with denatured alcohol or DOT 4 BRAKE
f1779x2x
FLUID. Wipe parts dry with a clean, lint free cloth. Blow
Wooden
out drilled passages and bores with a clean air supply.
Toothpick
Do not use a wire or similar instrument to clean drilled
passages.
2. Carefully inspect all components. Replace any parts that
appear damaged or worn.
a. Check pistons for pitting, scratching or corrosion on
face and also on ground surfaces.
b. Inspect caliper piston bore. Replace caliper if bore
shows signs of pitting or corrosion. Do not hone
bore for reuse.
Wiper
c. Always replace wipers, square seals and crossover
Square
O-rings after caliper disassembly.
Seal
1WARNING
Figure 2-60. Remove Wipers and Square Seals
Always replace brake pads in pairs. Never replace just
From Piston Bores
one brake pad. Mismatched brake pads can lead to brake
system damage and loss of braking performance, which
could result in death or serious injury.
e. Using a tapered, rubber-tipped nozzle on the air
hose (to prevent both loss of air pressure and dam-
3.
Inspect brake pads and discs. See INSPECTION at the
age to the banjo seating surface), apply low pres-
beginning of this section.
sure compressed air into the banjo bolt hole to force
4.
Inspect pad pins for wear and grooving. Replace both
pistons into contact with cushion of tool. See Figure
pins if wear of either pin exceeds 0.015 inch (0.38 mm).
2-59.
f.
Remove bridge bolts and separate caliper housings.
g. Remove pistons from caliper piston bores. For best
CALIPER ASSEMBLY
results, wiggle pistons slightly while pulling.
6.
Remove two crossover O-rings from inside caliper hous-
1.
Install new square seals into caliper piston bores.
ing. Discard O-rings.
2.
Install new wipers into caliper piston bores.
CAUTION
CAUTION
Do not use metal objects to remove parts from caliper
piston bores or damage will occur. Damaged pistons or
Do not use DOT 4 brake fluid for lubrication or in-
bores will leak when reassembled. Use a wooden tooth-
creased lever travel will result.
pick to assist in the removal of parts, if necessary.
3.
Lubricate the following areas using a thin film of G.E.
7. Using a wooden toothpick, remove wiper and square
VERSILUBE® #G322L SILICONE GREASE (marked
seal from each piston bore. Discard wipers and seals.
“Piston Lube” in the service parts kit):
See Figure 2-60.
● Inside diameter of square seals and wipers.
● Caliper piston bores.
● Nose radius and outside diameter of piston.
CLEANING AND INSPECTION
NOTE
All other surfaces must be kept clean and dry for assembly.
1WARNING
4. Carefully insert pistons into bores by hand. If resistance
Use denatured alcohol to clean brake system compo-
is felt, remove piston and verify that both seal and wiper
nents. Do not use mineral base solvents (such as gaso-
are properly installed.
line and paint thinner) or deterioration of rubber parts
5. Install new crossover O-rings into two grooves on inside
may occur after assembly. Deterioration of components
caliper housing.
may result in premature brake failure, which could result
in death or serious injury.
6. Assemble caliper housings as follows:
2-50
2005 Touring: Chassis
HOME
NOTE
If pad pins do not fit, verify the following: (1) Proper pad set is
being used, not two identical pads. (2) Anti-rattle spring is
installed as shown in Figure 2-61. (3) Pads are pushed tight
against anti-rattle spring.
Bleeder
Valve
CALIPER INSTALLATION
1.
Install calipers as follows:
a. Use shop rag or tape to protect fender area adja-
cent to caliper, as incidental contact can occur dur-
ing caliper installation.
b. Place caliper over brake disc with bleeder valve top-
side.
Anti-Rattle
Spring
c. Loosely install long caliper mounting bolt into upper
f1780x2x
lug of front fork leg.
Figure 2-61. Install Anti-Rattle Spring
d. Install short caliper mounting bolt into lower lug of
front fork leg. Tighten lower mounting bolt to 28-38
ft-lbs (37.9-51.5 Nm).
a. Install bleeder valve on outside caliper housing, if
e. Tighten upper caliper mounting bolt to 28-38 ft-lbs
removed. Tighten valve to 80-100 in-lbs (9.0-11.3
(37.9-51.5 Nm).
Nm). Install bleeder valve cap.
f.
Repeat step to install second caliper.
b. Place outside caliper housing on workbench with
decal side down. Place anti-rattle spring in channel
CAUTION
around boss. Spring is not directional. See Figure 2-
61.
To avoid leakage, verify that the washers, banjo bolt,
brake line and caliper bore are completely clean.
c. Mate inside and outside caliper housings and
2.
Connect brake line to caliper using two new steel/rubber
loosely install two bridge bolts.
washers and banjo bolt. Tighten bolt to
17-22 ft-lbs
d. Verify that anti-rattle spring is still seated.
(23.0-29.8).
3.
Remove two Phillips screws to release cover from front
e. Tighten bridge bolts to 28-38 ft-lbs (37.9-51.5 Nm).
brake master cylinder reservoir. Verify that brake fluid
NOTE
level is 1/8 inch (3.2 mm) below top of reservoir with
master cylinder in a level position. Add DOT 4 BRAKE
Both front calipers (as well as the rear brake caliper) use the
FLUID, if necessary.
same brake pad set.
7. Install new brake pads into caliper with the friction mate-
1WARNING
rial facing the brake disc opening. Also, be sure that the
Verify proper operation of the master cylinder relief port.
pad is oriented so that the curved side faces the rear of
A plugged or covered relief port can cause brake drag or
the vehicle when the caliper is installed. See Figure 2-
wheel lockup and may lead to loss of vehicle control,
57.
which could result in death or serious injury.
Furthermore, note that the backing plate of each brake
4.
Actuate the brake lever. A slight spurt of fluid will break
pad has either one or two tabs. On the right side of the
the surface if all internal components are working prop-
vehicle, the pad with two tabs is installed on the inboard
erly.
side of the caliper, the pad with the single tab is installed
on the outboard side.
1
WARNING
On the left side of the vehicle, the pad location is
reversed. Therefore, the pad with the single tab is
After installation of calipers and BEFORE moving motor-
installed on the inboard side of the caliper, while the pad
cycle, pump front brake hand lever until pistons push
with two tabs is installed on the outboard side.
pads against the brake discs. If fluid pressure is not
pumped up, the brake will not be available the first time it
8. Install pad pins and tighten to 180-200 in-lbs (20.3-22.6
is used, a situation that could result in death or serious
Nm).
injury.
2005 Touring: Chassis
2-51
HOME
5.
Depress front brake hand lever several times to set
8. Test ride the motorcycle. If the brakes feel spongy, bleed
brake pads to proper operating position within caliper.
the system again. See Section
2.14 BLEEDING
Bleed brake system. See Section
2.14 BLEEDING
HYDRAULIC BRAKES.
HYDRAULIC BRAKES.
NOTE
6.
Install master cylinder reservoir cover. Install two Phillips
screws to fasten cover to reservoir and tighten to 6-8 in-
To allow new brake pads to “wear in” properly with the brake
lbs (0.7-0.9 Nm).
disc, avoid making hard stops for the first 100 miles (160 km).
7.
Test operation of brake lamp with the front brake applied
and the Ignition/Light Key Switch turned to IGNITION.
1WARNING
After completing repairs or bleeding the system, always
test motorcycle brakes at low speed. If brakes are not
operating properly or braking efficiency is poor, testing
at high speeds may result in death or serious injury.
2-52
2005 Touring: Chassis
HOME
REAR BRAKE CALIPER
2.13
INSPECTION
Caliper
Check brake pads and discs:
● At every scheduled service interval.
● Whenever the components are removed during service
Rear Brake
procedures.
Top View
BRAKE DISC THICKNESS/WARPAGE
The minimum brake disc thickness is stamped on the side of
the disc. Replace disc if excessively worn or badly scored.
Maximum brake disc lateral runout or warpage is 0.008 inch
(0.2 mm) when measured near the outside diameter.
Replace disc if warped beyond specification. For replace-
ment instructions, see Section 2.4 REAR WHEEL, DISAS-
SEMBLY.
Backing
Friction
Plate
Material
Outer Pad
BRAKE PADS
NOTE
Brake pad inspection can be performed without removing the
caliper.
Brake
1. Look down at the back of the rear caliper. See Figure 2-
Disc
62.
f1757x2x
2. Place a thin plastic 6 inch rule against the brake disc and
Replace both pads if friction material of either pad is
measure the friction material of the brake outer pad.
0.04 inch (1.02 mm) or less above the backing plate.
Using a small hand mirror, visually check the friction
material of the inner pad.
Figure 2-62. Measure Brake Pad Wear
3. Repeat above checks at the front of the rear caliper.
Replace both pads If the friction material above the
REAR BRAKE PAD REPLACEMENT
backing plate on either pad is 0.04 inch (1.02 mm) thick
or less.
PAD REMOVAL/INSTALLATION
1WARNING
1.
Remove right side saddlebag. See Section 2.25 SAD-
Always replace brake pads in pairs. Never replace just
DLEBAG, REMOVAL.
one brake pad. Mismatched brake pads can lead to brake
system damage and loss of braking performance, which
2.
Loosen both pad pins, but do not remove. See Figure 2-
63.
could result in death or serious injury.
4. See REAR BRAKE PAD REPLACEMENT on this page.
CAUTION
Cover adjacent surfaces when removing, draining, filling
BRAKE LINE/HOSE INSPECTION
and/or bleeding brake system components. Spilling DOT
4 brake fluid on painted or other finished surfaces can
When checking brake pads and discs, take the time to
result in cosmetic damage. Immediately wipe up any
inspect the brake lines and hoses for damage or wear.
spilled brake fluid and thoroughly clean affected area
Replace as necessary.
with water or 50/50 mix of water and denatured alcohol.
2005 Touring: Chassis
2-53
HOME
10. Verify that inside pad is captured between brake disc
Pad
and pistons. Completely remove pad pins to free outside
Pins
brake pad. Note the orientation of the pad.
11. Install new outside brake pad using the same orienta-
tion. Curved portion of pad must face rear of motorcycle.
If the inside pad moved during the previous step, rein-
stall.
NOTE
Replacing one pad at a time keeps the anti-rattle spring in
place. Remove both pads to remove or replace the spring.
12. Inspect pad pins. See CLEANING AND INSPECTION,
step 4.
13. Install two pad pins and tighten to 180-200 in-lbs (20.3-
22.6 Nm).
f2026x2x
Bridge
Anchor
Bolts
Weldment
1WARNING
Figure 2-63. Loosen Both Pad Pins
After installation of new pads and BEFORE moving
motorcycle, pump rear brake pedal until pistons push
pads against the brake disc. If fluid pressure is not
pumped up, the rear brake will not be available the first
time it is used, a situation that could result in death or
CAUTION
serious injury.
To prevent dirt and other contaminants from entering the
master cylinder reservoir, thoroughly clean the cover
14.
Pump rear brake pedal to move pistons out until they
contact both brake pads. Verify piston location against
before removal.
pads.
3.
Remove two Phillips screws to release cover from rear
15.
Verify that brake fluid level is 1/8 inch (3.2 mm) below top
master cylinder reservoir.
of reservoir with master cylinder in a level position. Add
NOTE
DOT 4 BRAKE FLUID, if necessary. Install master cylin-
der reservoir cover. Install two Phillips screws to fasten
As the pistons are pushed back into the caliper, fluid level
cover to reservoir and tighten to 6-8 in-lbs (0.7-0.9 Nm).
may rise more than 1/8 inch (3.2 mm) and overflow the reser-
voir. Watch the fluid level as the pistons are retracted and
remove fluid from the reservoir if necessary.
4.
Pry the inside pad back pushing the pistons into their
Inboard Side
Outboard Side
of Caliper
of Caliper
bores. Use a putty knife with a wide thin blade to avoid
scoring or scratching the brake disc.
NOTE
Do not completely pull pad pins from caliper during the next
step. Completely removing pad pins at this time will make
Two Tabs
Single
assembly difficult.
Tab
5.
Once the pistons have been retracted, pull the pad pins
part way out until the inside pad drops free. Note the ori-
entation of the pad.
6.
Install new inside brake pad using the same orientation.
Curved portion of pad must face rear of motorcycle.
7. Install pad pins, but do not fully tighten.
Curved Portion
Faces Rear
8. Pump rear brake pedal to move inside pistons out until
they contact inside brake pad.
Right Side of Vehicle
9. Pry the outside pad back pushing the pistons into their
f2156x2x
bores. Use a putty knife with a wide thin blade to avoid
scoring or scratching the brake disc.
Figure 2-64. Rear Brake Pad Locations
2-54
2005 Touring: Chassis
HOME
1. Bridge Bolt (3)
12. Inner Brake Pad
15
2. Pad Pin (2)
13. Anti-Rattle Spring
3. Decal
14. Crossover O-Ring (2)
4. Outside Caliper Housing
15. Inside Caliper Housing
5. Rubber Damper
6. Bleeder Valve
13
7. Bleeder Valve Cap
8. Square Seal (4)
9. Wiper (4)
14
10. Piston (4)
10
11. Outer Brake Pad
6
8
7
10
9
8
12
11
9
2
3
1
4
5
f2072x2x
Figure 2-65. Rear Brake Caliper Assembly (Right Side)
16. Install right side saddlebag. See Section 2.25 SADDLE-
CALIPER REMOVAL
BAG, INSTALLATION.
17. Test operation of brake lamp with the rear brake applied
NOTE
and the Ignition/Light Key Switch turned to IGNITION.
If only replacing brake pads, see REAR BRAKE PAD
REPLACEMENT in this section.
1WARNING
1.
Block motorcycle underneath frame so rear wheel is
After completing repairs or bleeding the system, always
raised off the ground.
test motorcycle brakes at low speed. If brakes are not
2.
Remove saddlebags. See Section 2.25 SADDLEBAG,
operating properly or braking efficiency is poor, testing
REMOVAL.
at high speeds may result in death or serious injury.
18. Test ride the motorcycle. If the brakes feel spongy, bleed
CAUTION
the system again. See Section
2.14 BLEEDING
Damaged banjo bolt surfaces will leak when reassem-
HYDRAULIC BRAKES.
bled. Prevent damage to seating surfaces by carefully
NOTE
removing brake line components.
To allow new brake pads to “wear in” properly with the brake
3.
Remove banjo bolt and two steel/rubber washers to
disc, avoid making hard stops for the first 100 miles (160 km).
detach rear brake line from caliper. Discard washers.
2005 Touring: Chassis
2-55
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