Harley Davidson 2004 Touring Models. Service Manual — page 32
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 2-49.
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 2-48. 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 2-49. Remove Cartridge From Reservoir Adapter
retaining ring from groove in clevis and then carefully
release spring. See Figure 2-48. Discard retaining ring.
2-42
2004 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 2-50. 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:
2004 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
through nipple until top of glass is flush with top of
Push Rod
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 2-51. 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 D.O.T.
5 SILICONE HYDRAULIC 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 2-51.
Reservoir
f2055x2x
1WARNING
Always wear proper eye protection when installing re-
Figure 2-52. 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
on push rod to compress spring, fit captured spacer
7. Lubricate new O-rings with D.O.T.
5 SILICONE
washer into cartridge body. Further compressing spring
HYDRAULIC BRAKE FLUID and carefully install in
as necessary, install retaining ring positioned in step 4 in
grooves on outside of cartridge body.
groove of cartridge body bore.
2-44
2004 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 2-53. Rear Brake Master Cylinder Assembly (Cross Sectional View)
8. Wipe bore of reservoir adapter with D.O.T. 5 SILICONE
14. Place large flat washer on top of dust boot fitting inside
HYDRAULIC BRAKE FLUID.
tabs in slot of clevis.
9. Insert cartridge body into reservoir adapter indexing tab
15. Push down on large flat washer to compress spring.
on adapter in slot on threaded end of cartridge. Use
While holding spring in a compressed state, install new
hand pressure only. Cartridge body is fully installed
retaining ring in groove of clevis.
when reservoir adapter contacts large retaining ring.
16. Pull down dust boot as necessary to seat over lip on res-
10. Stand master cylinder assembly upright on banjo sealing
ervoir adapter.
surface. For best results, suspend reservoir over edge of
17. Rotate boot so that drain/air hole is at the bottom.
table. Be sure to lay down a clean shop cloth to protect
the sealing surface from damage.
18. See BRAKE PEDAL/MASTER CYLINDER ASSEMBLY,
INSTALLATION, in this section.
11. Install spring over push rod and cartridge body until it
contacts side of large retaining ring. See Figure 2-52.
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.
2004 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.
BRAKE DISC THICKNESS/WARPAGE
Right
Front Brake
The minimum brake disc thickness is stamped on the side of
Bottom View
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
Replace disc if warped beyond specification. For replace-
Material
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
caliper.
Replace both pads if friction material of either pad is
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
2-54.
Figure 2-54. Measure Brake Pad Wear
2. Place a thin plastic 6 inch rule against the brake disc and
measure the friction material of the brake outer pad.
Using a small hand mirror, visually check the friction
FRONT BRAKE PAD
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
backing plate on either pad is 0.04 inch (1.02 mm) thick
PAD REMOVAL
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-
Always replace brake pads in pairs. Never replace just
55.
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
4.
Remove two Phillips screws to release cover from front
page.
master cylinder reservoir.
NOTE
BRAKE LINE/HOSE INSPECTION
As the pistons are pushed back into the caliper, fluid level
may rise more than 1/8 inch (3.2 mm) and overflow the reser-
When checking brake pads and discs, take the time to
inspect the brake lines and hoses for damage or wear.
voir. Watch the fluid level as the pistons are retracted and
remove fluid from the reservoir if necessary.
Replace as necessary.
2-46
2004 Touring: Chassis
HOME
PAD INSTALLATION
Upper Caliper
Mounting Bolt
NOTE
(Long)
Both front calipers (as well as the rear brake caliper) use the
Pad
same brake pad set.
Pins
1.
Install new brake pads into caliper with the friction mate-
rial facing the brake disc opening. Be sure that the pad is
oriented so that the curved side faces the rear of the
vehicle when the caliper is installed. See Figure 2-56.
Furthermore, note that the backing plate of each brake
pad has either one or two tabs. On the right side of the
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.
On the left side of the vehicle, the pad location is
reversed. Therefore, the pad with the single tab is
installed on the inboard side of the caliper, while the pad
Lower Caliper
with two tabs is installed on the outboard side.
Mounting Bolt
f1767x2x
(Short)
2.
Install pad pins, but do not fully tighten at this time.
3.
Install calipers as follows:
Figure 2-55. Loosen Pad Pins and Remove Caliper
Mounting Bolts (Right Side View)
a. Use shop rag or tape to protect fender area adja-
cent to caliper, as incidental contact can occur dur-
ing caliper installation.
5.
Pry back inner and outer brake pads pushing the four
b. Place caliper over brake disc with bleeder valve top-
pistons back into their bores.
side.
6.
With the pistons retracted, remove two pad pins and
c. Loosely install long caliper mounting bolt into upper
both inner and outer brake pads. Inspect pad pins. See
lug of front fork leg.
CLEANING AND INSPECTION, step 4.
d. Install short caliper mounting bolt into lower lug of
front fork leg. Tighten lower mounting bolt to 28-38
NOTE
ft-lbs (37.9-51.5 Nm).
Replacing one pad at a time keeps the anti-rattle spring in
e. Tighten upper caliper mounting bolt to 28-38 ft-lbs
place. Remove both pads to remove or replace the spring.
(37.9-51.5 Nm).
f.
Tighten pad pins to 180-200 in-lbs (20.3-22.6 Nm).
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 2-56. Front Brake Pad Locations
2004 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 2-57. Front Brake Caliper Assembly (Left Side)
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.
4. Pump brake hand lever until pistons contact brake pads
8.
Test ride the motorcycle. If the brakes feel spongy, bleed
and pads contact brake discs. Verify piston location
the system. See Section 2.14 BLEEDING HYDRAULIC
against pads. If the front wheel is off the ground, rotate
BRAKES.
wheel to check for excessive brake pad drag.
NOTE
5. Verify that brake fluid level is 1/8 inch (3.2 mm) below top
To allow new brake pads to “wear in” properly with the brake
of reservoir with master cylinder in a level position. Add
disc, avoid making hard stops for the first 100 miles (160 km).
D.O.T. 5 SILICONE BRAKE FLUID, if necessary.
6. Install master cylinder reservoir cover. Install two Phillips
screws to fasten cover to reservoir and tighten to 6-8 in-
lbs (0.7-0.9 Nm).
2-48
2004 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 2-58. Direct Compressed Air Into Banjo Bolt Hole to Force Pistons From Bores
2.
Remove two bridge bolts and separate inside and out-
CALIPER REMOVAL
side caliper housings.
3.
Remove anti-rattle spring from channel around boss in
NOTE
outside caliper housing.
If only replacing brake pads, see FRONT BRAKE PAD
4.
Remove bleeder valve, if damaged.
REPLACEMENT in this section.
1WARNING
CAUTION
Pressurized air can blow debris into your face and eyes.
Damaged banjo bolt surfaces will leak when reassem-
Always wear eye protection or a face shield. Failure to do
bled. Prevent damage to seating surfaces by carefully
so could result in eye injury.
removing brake line components.
5.
Remove four pistons as follows:
1. Remove banjo bolt and two steel/rubber washers to
a. Obtain BRAKE CALIPER PISTON REMOVER (Part
detach front brake line from caliper. Discard washers.
No. HD-43293A). See inset of Figure 2-58.
2. Use shop rag or tape to protect fender area adjacent to
b. Seat tool in outside caliper housing aligning outside
caliper, as incidental contact can occur during caliper
holes in tool with bridge bolt holes in housing. Place
removal.
inside caliper housing over tool aligning bridge bolt
holes with outside holes in tool.
3. Remove upper and lower caliper mounting bolts from
front fork mounting lugs. Lift caliper upward to remove
c. Install bridge bolts and tighten securely.
from brake disc.
d. If the bleeder valve was removed, reinstall finger
tight or place a gloved finger over the valve hole.
e. Using a tapered, rubber-tipped nozzle on the air
hose (to prevent both loss of air pressure and dam-
CALIPER DISASSEMBLY
age to the banjo seating surface), apply low pres-
sure compressed air into the banjo bolt hole to force
1. See Figure 2-55. Remove two pad pins. Remove brake
pistons into contact with cushion of tool. See Figure
pads from caliper housings.
2-58.
2004 Touring: Chassis
2-49
HOME
2. Carefully inspect all components. Replace any parts that
f1779x2x
appear damaged or worn.
Wooden
Toothpick
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.
c. Always replace wipers, square seals and crossover
O-rings after caliper disassembly.
1WARNING
Wiper
Always replace brake pads in pairs. Never replace just
Square
one brake pad. Mismatched brake pads can lead to brake
Seal
system damage and loss of braking performance, which
could result in death or serious injury.
Figure 2-59. Remove Wipers and Square Seals
3.
Inspect brake pads and discs. See INSPECTION at the
From Piston Bores
beginning of this section.
4.
Inspect pad pins for wear and grooving. Replace both
pins if wear of either pin exceeds 0.015 inch (0.38 mm).
f.
Remove bridge bolts and separate caliper housings.
g. Remove pistons from caliper piston bores. For best
results, wiggle pistons slightly while pulling.
6.
Remove two crossover O-rings from inside caliper hous-
CALIPER ASSEMBLY
ing. Discard O-rings.
1.
Install new square seals into caliper piston bores.
CAUTION
2.
Install new wipers into caliper piston bores.
Do not use metal objects to remove parts from caliper
piston bores or damage will occur. Damaged pistons or
CAUTION
bores will leak when reassembled. Use a wooden tooth-
pick to assist in the removal of parts, if necessary.
Do not use D.O.T. 5 brake fluid for lubrication or in-
creased lever travel will result.
7. Using a wooden toothpick, remove wiper and square
seal from each piston bore. Discard wipers and seals.
3.
Lubricate the following areas using a thin film of G.E.
See Figure 2-59.
VERSILUBE® #G322L SILICONE GREASE (marked
“Piston Lube” in the service parts kit):
● Inside diameter of square seals and wipers.
CLEANING AND INSPECTION
● Caliper piston bores.
● Nose radius and outside diameter of piston.
NOTE
1WARNING
All other surfaces must be kept clean and dry for assembly.
Use denatured alcohol to clean brake system compo-
nents. Do not use mineral base solvents (such as gaso-
4. Carefully insert pistons into bores by hand. If resistance
line and paint thinner) or deterioration of rubber parts
is felt, remove piston and verify that both seal and wiper
may occur after assembly. Deterioration of components
are properly installed.
may result in premature brake failure, which could result
5. Install new crossover O-rings into two grooves on inside
in death or serious injury.
caliper housing.
1. Clean all parts with denatured alcohol or D.O.T. 5 SILI-
6. Assemble caliper housings as follows:
CONE BRAKE FLUID. Wipe parts dry with a clean, lint
free cloth. Blow out drilled passages and bores with a
a. Install bleeder valve on outside caliper housing, if
clean air supply. Do not use a wire or similar instrument
removed. Tighten valve to 80-100 in-lbs (9.0-11.3
to clean drilled passages.
Nm). Install bleeder valve cap.
2-50
2004 Touring: Chassis
HOME
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-
Bleeder
ing caliper installation.
Valve
b. Place caliper over brake disc with bleeder valve top-
side.
c. Loosely install long caliper mounting bolt into upper
lug of front fork leg.
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).
Anti-Rattle
e. Tighten upper caliper mounting bolt to 28-38 ft-lbs
Spring
f1780x2x
(37.9-51.5 Nm).
f.
Repeat step to install second caliper.
Figure 2-60. Install Anti-Rattle Spring
CAUTION
b. Place outside caliper housing on workbench with
decal side down. Place anti-rattle spring in channel
To avoid leakage, verify that the washers, banjo bolt,
around boss. Spring is not directional. See Figure 2-
brake line and caliper bore are completely clean.
60.
2.
Connect brake line to caliper using two new steel/rubber
c. Mate inside and outside caliper housings and
washers and banjo bolt. Tighten bolt to
17-22 ft-lbs
loosely install two bridge bolts.
(23.0-29.8).
d. Verify that anti-rattle spring is still seated.
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
level is 1/8 inch (3.2 mm) below top of reservoir with
NOTE
master cylinder in a level position. Add D.O.T. 5 SILI-
Both front calipers (as well as the rear brake caliper) use the
CONE BRAKE 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,
56.
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
vehicle, the pad with two tabs is installed on the inboard
the surface if all internal components are working prop-
side of the caliper, the pad with the single tab is installed
erly.
on the outboard side.
On the left side of the vehicle, the pad location is
1WARNING
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
8. Install pad pins and tighten to 180-200 in-lbs (20.3-22.6
pumped up, the brake will not be available the first time it
Nm).
is used, a situation that could result in death or serious
injury.
NOTE
If pad pins do not fit, verify the following: (1) Proper pad set is
5.
Depress front brake hand lever several times to set
being used, not two identical pads. (2) Anti-rattle spring is
brake pads to proper operating position within caliper.
installed as shown in Figure 2-60. (3) Pads are pushed tight
Bleed brake system. See Section
2.14 BLEEDING
against anti-rattle spring.
HYDRAULIC BRAKES.
2004 Touring: Chassis
2-51
HOME
6.
Install master cylinder reservoir cover. Install two Phillips
8. Test ride the motorcycle. If the brakes feel spongy, bleed
screws to fasten cover to reservoir and tighten to 6-8 in-
the system again. See Section
2.14 BLEEDING
lbs (0.7-0.9 Nm).
HYDRAULIC BRAKES.
7.
Test operation of brake lamp with the front brake applied
NOTE
and the Ignition/Light Key Switch turned to IGNITION.
To allow new brake pads to “wear in” properly with the brake
disc, avoid making hard stops for the first 100 miles (160 km).
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
2004 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
61.
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 2-61. 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-
DLEBAG, REMOVAL.
Always replace brake pads in pairs. Never replace just
one brake pad. Mismatched brake pads can lead to brake
2.
Loosen both pad pins, but do not remove. See Figure 2-
system damage and loss of braking performance, which
62.
could result in death or serious injury.
3.
Remove two Phillips screws to release cover from rear
4. See REAR BRAKE PAD REPLACEMENT on this page.
master cylinder reservoir.
NOTE
BRAKE LINE/HOSE INSPECTION
As the pistons are pushed back into the caliper, fluid level
may rise more than 1/8 inch (3.2 mm) and overflow the reser-
When checking brake pads and discs, take the time to
voir. Watch the fluid level as the pistons are retracted and
inspect the brake lines and hoses for damage or wear.
remove fluid from the reservoir if necessary.
Replace as necessary.
2004 Touring: Chassis
2-53
HOME
13. Install two pad pins and tighten to 180-200 in-lbs (20.3-
Pad
22.6 Nm).
Pins
1WARNING
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
serious injury.
14. Pump rear brake pedal to move pistons out until they
contact both brake pads. Verify piston location against
pads.
f2026x2x
15. Verify that brake fluid level is 1/8 inch (3.2 mm) below top
Bridge
Anchor
of reservoir with master cylinder in a level position. Add
Bolts
Weldment
D.O.T. 5 SILICONE BRAKE FLUID, if necessary. Install
master cylinder reservoir cover. Install two Phillips
Figure 2-62. Loosen Both Pad Pins
screws to fasten cover to reservoir and tighten to 6-8 in-
lbs (0.7-0.9 Nm).
4.
Pry the inside pad back pushing the pistons into their
16. Install right side saddlebag. See Section 2.25 SADDLE-
bores. Use a putty knife with a wide thin blade to avoid
BAG, INSTALLATION.
scoring or scratching the brake disc.
17. Test operation of brake lamp with the rear brake applied
NOTE
and the Ignition/Light Key Switch turned to IGNITION.
Do not completely pull pad pins from caliper during the next
step. Completely removing pad pins at this time will make
1WARNING
assembly difficult.
After completing repairs or bleeding the system, always
5.
Once the pistons have been retracted, pull the pad pins
test motorcycle brakes at low speed. If brakes are not
part way out until the inside pad drops free. Note the ori-
operating properly or braking efficiency is poor, testing
entation of the pad.
at high speeds may result in death or serious injury.
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.
Inboard Side
Outboard Side
of Caliper
of Caliper
8.
Pump rear brake pedal to move inside pistons out until
they contact inside brake pad.
9.
Pry the outside pad back pushing the pistons into their
bores. Use a putty knife with a wide thin blade to avoid
scoring or scratching the brake disc.
Two Tabs
Single
10. Verify that inside pad is captured between brake disc
Tab
and pistons. Completely remove pad pins to free outside
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
Curved Portion
Faces Rear
Replacing one pad at a time keeps the anti-rattle spring in
place. Remove both pads to remove or replace the spring.
Right Side of Vehicle
f2156x2x
12. Inspect pad pins. See CLEANING AND INSPECTION,
step 4.
Figure 2-63. Rear Brake Pad Locations
2-54
2004 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 2-64. Rear Brake Caliper Assembly (Right Side)
18. Test ride the motorcycle. If the brakes feel spongy, bleed
the system again. See Section
2.14 BLEEDING
CAUTION
HYDRAULIC BRAKES.
Damaged banjo bolt surfaces will leak when reassem-
NOTE
bled. Prevent damage to seating surfaces by carefully
To allow new brake pads to “wear in” properly with the brake
removing brake line components.
disc, avoid making hard stops for the first 100 miles (160 km).
3.
Remove banjo bolt and two steel/rubber washers to
detach rear brake line from caliper. Discard washers.
4.
Remove rear wheel. See Section 2.4 REAR WHEEL,
CALIPER REMOVAL
REMOVAL, steps 2-6.
5.
Remove caliper from anchor weldment on rear swing-
arm.
NOTE
If only replacing brake pads, see REAR BRAKE PAD
REPLACEMENT in this section.
CALIPER DISASSEMBLY
1. Block motorcycle underneath frame so rear wheel is
1.
See Figure 2-62. Remove two pad pins. Remove brake
raised off the ground.
pads from caliper housings.
2. Remove saddlebags. See Section 2.25 SADDLEBAG,
2.
Remove three bridge bolts and separate inside and out-
REMOVAL.
side caliper housings.
2004 Touring: Chassis
2-55
HOME
f1781x2x
Brake Caliper
Brake Caliper Piston Remover
Piston Remover
(Part No. HD-43293A)
Bridge
CAUTION
Bolt
To prevent air from escaping through the banjo
bolt hole, and to avoid scratching or nicking the
banjo seating surface, use only a tapered, rubber
tipped nozzle on air hose. Loss of air pressure
Low Pressure
will keep the pistons from moving, while any
Tapered,
Air Hose
damage to the banjo seating surface requires
Rubber-Tipped
caliper replacement.
Nozzle
Figure 2-65. Direct Compressed Air Into Banjo Bolt Hole to Force Pistons From Bores
3.
Remove anti-rattle spring from channel around boss in
7. Remove two crossover O-rings from inside caliper hous-
outside caliper housing.
ing. Discard O-rings.
4.
If damaged, cut anchor of rubber damper and remove.
CAUTION
5.
Remove bleeder valve, if damaged.
Do not use metal objects to remove parts from caliper
1WARNING
piston bores or damage will occur. Damaged pistons or
bores will leak when reassembled. Use a wooden tooth-
Pressurized air can blow debris into your face and eyes.
pick to assist in the removal of parts, if necessary.
Always wear eye protection or a face shield. Failure to do
8.
Using a wooden toothpick, remove wiper and square
so could result in eye injury.
seal from each piston bore. Discard wipers and seals.
6. Remove four pistons as follows:
See Figure 2-66.
a. Obtain BRAKE CALIPER PISTON REMOVER (Part
No. HD-43293A). See inset of Figure 2-65.
Wooden
f1779x2x
b. Seat tool in outside caliper housing aligning holes in
Toothpick
tool with three bridge bolt holes in housing. Place
inside caliper housing over tool aligning bridge bolt
holes with three holes in tool.
c. Install bridge bolts and tighten securely.
d. If the bleeder valve was removed, reinstall finger
tight or place a gloved finger over the valve hole.
e. Using a tapered, rubber-tipped nozzle on the air
hose (to prevent both loss of air pressure and dam-
age to the banjo seating surface), apply low pres-
sure compressed air into the banjo bolt hole to force
Wiper
pistons into contact with cushion of tool. See Figure
Square
2-65.
Seal
f.
Remove bridge bolts and separate caliper housings.
g. Remove pistons from caliper piston bores. For best
Figure 2-66. Remove Wipers and Square Seals
results, wiggle pistons slightly while pulling.
From Piston Bores
2-56
2004 Touring: Chassis
HOME
CLEANING AND INSPECTION
f1782x2x
Rubber
1WARNING
Damper
Anchor Bead
Use denatured alcohol to clean brake system compo-
nents. Do not use mineral base solvents (such as gaso-
line and paint thinner) or deterioration of rubber parts
may occur after assembly. Deterioration of components
Anti-Rattle
may result in premature brake failure, which could result
Spring
Bleeder
in death or serious injury.
Valve
1.
Clean all parts with denatured alcohol or D.O.T. 5 SILI-
CONE BRAKE FLUID. Wipe parts dry with a clean, lint
free cloth. Blow out drilled passages and bores with a
clean air supply. 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.
Figure 2-67. Install Anti-Rattle Spring
a. Check pistons for pitting, scratching or corrosion on
face and also on ground surfaces.
b. Inspect caliper piston bore. Replace caliper if bore
● Inside diameter of square seals and wipers.
shows signs of pitting or corrosion. Do not hone
● Caliper piston bores.
bore for reuse.
● Nose radius and outside diameter of piston.
c. Check rubber damper for cuts, tears or signs of
deterioration.
NOTE
d. Always replace wipers, square seals and crossover
All other surfaces must be kept clean and dry for assembly.
O-rings after caliper disassembly.
4.
Carefully insert pistons into bores by hand. If resistance
is felt, remove piston and verify that both seal and wiper
1WARNING
are properly installed.
Always replace brake pads in pairs. Never replace just
5.
Install new crossover O-rings into two grooves on inside
one brake pad. Mismatched brake pads can lead to brake
caliper housing.
system damage and loss of braking performance, which
could result in death or serious injury.
6.
Assemble caliper housings as follows:
a. Install bleeder valve on outside caliper housing, if
3.
Inspect brake pads and discs. See INSPECTION at the
removed. Tighten valve to 80-100 in-lbs (9.0-11.3
beginning of this section.
Nm). Install bleeder valve cap.
4. Inspect pad pins for wear and grooving. Replace both
b. Place outside caliper housing on workbench with
pins if wear of either pin exceeds 0.015 inch (0.38 mm).
decal side down. Place anti-rattle spring in channel
around boss. Spring is not directional. See Figure 2-
67.
CALIPER ASSEMBLY
c. Mate inside and outside caliper housings and
loosely install two bridge bolts.
1. Install new square seals into caliper piston bores.
d. Tighten bridge bolts to 28-38 ft-lbs (37.9-51.5 Nm).
2. Install new wipers into caliper piston bores.
e. If rubber damper was removed, lubricate anchor of
new damper with isopropyl alcohol or glass cleaner
CAUTION
and install by pulling rubber bead through hole in
outside caliper housing, as shown in Figure 2-67.
Do not use D.O.T. 5 brake fluid for lubrication or in-
creased lever travel will result.
f.
Verify that anti-rattle spring is still seated.
3. Lubricate the following areas using a thin film of G.E.
NOTE
VERSILUBE® #G322L SILICONE GREASE (marked
“Piston Lube” in the service parts kit):
All calipers (both front and rear) use the same brake pad set.
2004 Touring: Chassis
2-57
HOME
7.
Install new brake pads into caliper with the friction mate-
5. Depress rear brake pedal several times to set brake
rial facing the brake disc opening. Also, be sure that the
pads to proper operating position within caliper. Bleed
pad is oriented so that the curved side faces the rear of
brake system. See Section 2.14 BLEEDING HYDRAU-
the vehicle when the caliper is installed. See Figure 2-
LIC BRAKES.
63.
6. Install master cylinder reservoir cover. Install two Phillips
Furthermore, note that the backing plate of each brake
screws to fasten cover to reservoir and tighten to 6-8 in-
pad has either one or two tabs. The pad with two tabs is
lbs (0.7-0.9 Nm).
installed on the inboard side of the caliper, the pad with
7. Install saddlebags. See Section
2.25 SADDLEBAG,
the single tab is installed on the outboard side.
INSTALLATION.
8.
Install pad pins and tighten to 180-200 in-lbs (20.3-22.6
Nm).
8. Test operation of brake lamp with the rear brake applied
and the Ignition/Light Key Switch turned to IGNITION.
NOTE
If pad pins do not fit, verify the following: (1) Proper pad set is
1WARNING
being used, not two identical pads. (2) Anti-rattle spring is
installed as shown in Figure 2-67. (3) Pads are pushed tight
After completing repairs or bleeding the system, always
against anti-rattle spring.
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.
CALIPER INSTALLATION
9.
Test ride the motorcycle. If the brakes feel spongy, bleed
the system again. See Section
2.14 BLEEDING
1.
Install rear wheel. See Section
2.4 REAR WHEEL,
HYDRAULIC BRAKES.
INSTALLATION, steps 1-9.
NOTE
CAUTION
To allow new brake pads to “wear in” properly with the brake
disc, avoid making hard stops for the first 100 miles (160 km).
To avoid leakage, verify that the washers, banjo bolt,
brake line and caliper bore are completely clean.
2. Connect brake line to caliper using two new steel/rubber
washers and banjo bolt. Tighten bolt to
17-22 ft-lbs
(23.0-29.8).
3.
Remove two Phillips screws to release cover from rear
brake master cylinder reservoir. Verify that brake fluid
level is 1/8 inch (3.2 mm) below top of reservoir with
master cylinder in a level position. Add D.O.T. 5 SILI-
CONE BRAKE FLUID, if necessary.
1WARNING
Verify proper operation of the master cylinder relief port.
A plugged or covered relief port can cause brake drag or
lockup, which may result in loss of vehicle control and
could result in death or serious injury.
4. Actuate the brake pedal with the cover removed. A slight
spurt of fluid will break the surface if all internal compo-
nents are working properly.
1WARNING
After installation of caliper and BEFORE moving motor-
cycle, 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 serious
injury.
2-58
2004 Touring: Chassis
HOME
BLEEDING HYDRAULIC BRAKES
2.14
6.
Repeat steps 3-5 until all air bubbles are purged.
GENERAL
7.
Final tighten the bleeder valve to
80-100 in-lbs
(9.0-11.3 Nm). Install the bleeder cap.
Bleed the hydraulic brake system any time a brake line, mas-
ter cylinder or brake caliper has been opened or disassem-
8.
Add brake fluid to the master cylinder reservoir until the
bled, or whenever the brake lever/pedal operation feels
fluid level is about 1/8 inch (3.2 mm) from the top. Do not
“spongy.” Bleeding evacuates air from the system leaving
reuse brake fluid.
only incompressible hydraulic fluid.
9.
Install the master cylinder reservoir cover. Install two
Phillips screws to fasten the cover to the reservoir.
NOTE
Tighten the screws to 6-8 in-lbs (0.7-0.9 Nm).
Harley-Davidson recommends that all brake service be per-
NOTE
formed by a Harley-Davidson dealer or other qualified techni-
cian.
Note that the angular shape of the front brake master cylin-
der reservoir cover makes one side thicker than the other.
NOTE
Install the cover on the master cylinder reservoir so that the
thicker side is positioned above the brake line fitting.
Hydraulic brake fluid bladder-type pressure equipment can
be used to fill brake master cylinders through the bleeder
valve. Remove master cylinder reservoir cover so that sys-
1WARNING
tem cannot pressurize. Do not use pressure bleeding equip-
After completing repairs or bleeding the system, always
ment when the hydraulic system is sealed with master
test motorcycle brakes at low speed. If brakes are not
cylinder reservoir cover and gasket in place.
operating properly or braking efficiency is poor, testing
at high speeds could result in death or serious injury.
1. Install end of a length of plastic tubing over caliper
bleeder valve. Place free end of tube in a clean con-
10.
Test ride motorcycle. Repeat the bleeding procedure if
tainer. See Figure 2-68. Stand motorcycle upright.
brakes feel spongy.
CAUTION
To prevent dirt and other contaminants from entering the
master cylinder reservoir, thoroughly clean the cover
before removal.
2. Remove the two Phillips screws to release cover from
the master cylinder reservoir.
3. Add D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID to
the master cylinder reservoir until the fluid level is 1/8
inch (3.2 mm) from the top. Do not reuse brake fluid.
NOTE
D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID is non-toxic.
4. Depress and hold brake lever/pedal to build up hydraulic
pressure.
5. Open bleeder valve about 1/2 turn. Brake fluid will flow
from bleeder valve through tubing. Close bleeder valve
when brake lever/pedal has moved 1/2 to 3/4 of its full
f1994x2x
range of travel. Allow brake lever/pedal to return slowly
to its released position.
Figure 2-68. Bleeding Hydraulic System
2004 Touring: Chassis
2-59
HOME
FRONT FORKS
2.15
CHANGING FORK OIL
Fork
Cap Bolt
Overhaul the front fork assembly and replace the fork oil at
every 50,000 mile (80,000 km) service interval. Proceed as
follows:
Table 2-2. Fork Oil Requirements
AMOUNT
FORK
MODEL
TYPE
OZ.
ML
IN.
MM
Fork Stop
All models
10.0
295
4.21
107
except
Cartridge
Left
Road King
See Warning Below
Road King
Conventional
11.1
328
5.24
133
Right
All models
Pinch Bolt
8312
1WARNING
Figure 2-69. Remove Fork Cap Bolt (FLHR/C/S Shown)
Fork oil level in cartridge type forks is carefully mea-
sured from top of tube after pumping damper rod. Any
deviation from instructions can result in incorrect
amount of fork oil. Incorrect amount of fork oil can
adversely affect handling and lead to loss of vehicle
control, which could result in death or serious injury.
NOTE
All touring models with the exception of Road King have the
cartridge type fork on the left side and the conventional type
fork on the right. Road King uses the conventional type fork
on both sides. To change the fork oil on a cartridge type fork,
partial disassembly of the fork is required.
FLHT/C/U, FLTR
Drain
1.
Remove left fork. See REMOVAL, steps 1-9.
Plug
f1786x2x
2.
Partially disassemble left fork. See DISASSEMBLY,
LEFT FORK, steps 1-13.
Figure 2-70. Remove Fork Oil Drain Plug
(Right Side Shown)
3.
Position fork assembly upside down over drain pan.
Allow sufficient time for fork to thoroughly drain (about
10-15 minutes).
FLHR/C/S
4.
Assemble left fork. See ASSEMBLY, LEFT FORK, steps
1.
Remove headlamp nacelle. See Section 2.31 WIND-
13-29.
SHIELD/HEADLAMP
NACELLE
(FLHR/C/S),
NACELLE REMOVAL
(FLHR/C) or NACELLE
5.
Drain and fill right fork. Removal and disassembly of the
fork is not required. See FLHR/C/S below, steps 3-7.
REMOVAL (FLHRS).
2.
Place suitable blocking under frame to raise front wheel
NOTE
several inches off the floor. Use an hydraulic center
If removing and inverting right fork is the preferred method of
stand on a level surface.
draining, see REMOVAL, steps 4-9.
3.
Remove fork cap bolt from fork tube plug at top of fork
tube. See Figure 2-69.
6.
Install fork(s) and assemble motorcycle. See INSTALLA-
TION in this section.
4.
Remove the drain plug from the bottom of the fork slider.
See Figure 2-70.
2-60
2004 Touring: Chassis
HOME
5. When fork oil is fully drained, install drain plug and
tighten to 72-96 in-lbs (8-11 Nm).
Vise Grip
6. Using a funnel, pour 11.1 ounces (328 ml) of Harley-
Davidson Type E Fork Oil into the fork tube.
Plastic Knob
7. Install fork cap bolt and tighten to 50-60 ft-lbs (68-81
Nm).
8. Repeat steps 3-7 on other fork.
9. Install headlamp nacelle. See Section
2.31 WIND-
SHIELD/HEADLAMP NACELLE (FLHR/C/S), NACELLE
INSTALLATION (FLHR/C) or NACELLE INSTALLATION
(FLHRS).
Rubber Pad
NOTE
If fork is leaking or fails visual inspection, completely disas-
Figure 2-71. Fork Tube Holder (HD-41177)
semble following the instructions under REMOVAL and DIS-
ASSEMBLY. Use the occasion to thoroughly examine all
parts and install a new fork oil seal.
Flat
f1898x2x
Fork Tube
REMOVAL
Plug
1.
Place suitable blocking under frame to raise front wheel
Fork Tube
several inches off the floor. For best results, use an
Holder
Vise
hydraulic center stand on a level surface.
2.
Remove the front wheel and fender. See Section 2.32
FRONT FENDER, REMOVAL.
3.
FLHT/C/U:
a. Remove fairing cap. See Section
2.29 UPPER
FAIRING/WINDSHIELD
(FLHT/C/U), FAIRING
CAP, REMOVAL.
b. Move to front of motorcycle. Loosen two upper outer
Figure 2-72. Install Fork Tube Into Fork Holder
fairing screws. Remove two lower outer fairing
screws.
c. Remove two screws from lower fork bracket to
7.
Holding fork slider to prevent fork from dropping, remove
release passing lamp bracket, chrome skirt and
fork cap bolt from fork tube plug. Slide fork tube down
inner fairing. Remove chrome skirt.
and out of upper fork bracket, fork stop, lower fork
bracket, and slider cover.
FLTR:
8.
Thread fork cap bolt back into fork tube plug to prevent
a. Remove instrument nacelle. See Section
2.30
loss of fork oil while handling.
UPPER FAIRING/WINDSHIELD (FLTR), INSTRU-
MENT NACELLE, REMOVAL.
9.
Move front fork to bench area. Place suitable drain pan
on floor beneath vise.
FLHR/C/S:
10.
Repeat steps 4-9 to remove right fork.
a. Remove headlamp nacelle. See Section
2.31
WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S),
NACELLE REMOVAL
(FLHR/C) or NACELLE
REMOVAL (FLHRS).
DISASSEMBLY
4.
Standing at front of vehicle, loosen pinch bolt (with lock-
washer) on left side of lower fork bracket, but do not
LEFT FORK
remove. See Figure 2-69.
Cartridge Type - All Models Except Road King
5.
Loosen fork cap bolt from fork tube plug at top of fork
tube, but do not remove.
NOTE
6.
Spray glass cleaner on fork tube above the rubber fork
Since Road King uses the conventional type fork on both
stop. After lubricating surfaces, move fork stop up fork
sides, see DISASSEMBLY, RIGHT FORK, for Road King
tube until it contacts bottom of upper fork bracket.
instructions.
2004 Touring: Chassis
2-61
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