BRAKES
489
brake caliper(s). When purchasing a new hose,
123
compare it to the old hose to make sure that the
length and angle of the steel hose portion are cor-
rect. Install new banjo bolt washers at both ends.
CAUTION
Do not spill any brake fluid on the
front fork or front wheel. Wash brake
fluid off any painted, plated or plastic
surfaces immediately, as it will dam-
age most surfaces it contacts. Use
soapy water and rinse completely.
1. Drain the front brake system as follows:
snap ring (B). Make sure the snap ring is correctly
a. Connect a hose over the bleed valve.
seated in the cartridge groove (Figure 120).
b. Insert the loose end of the hose in a container
7. Install the spring and spring seat (A, Figure 121)
to catch the brake fluid.
onto the pushrod.
c. Open the bleed valve and apply the front
8. Install the boot (B, Figure 121), washer (C) and
brake lever to pump the fluid out of the master
snap ring (D). Make sure the snap ring (A, Figure
cylinder and brake line. Continue until the
110) is correctly seated in the push rod groove.
fluid is removed.
9. Connect the brake rod (Figure 109) onto the
master cylinder and tighten the locknut securely.
d. Close the bleed valve and disconnect the
10. Install the diaphragm and reservoir cover.
hose.
11. Install the master cylinder as described in this
e. On models with dual front brakes, repeat for
chapter.
the opposite side.
f. Dispose of this brake fluid—never reuse
WARNING
brake fluid. Contaminated brake fluid will
Do not ride the motorcycle until the
cause brake failure.
rear brake is operating correctly with
2. Before removing the brake line(s), note the
full hydraulic advantage. If neces-
sary, bleed the brake as described in
brake line routing from the master cylinder to the
this chapter.
caliper(s). In addition, note the number and position
12
of the metal hose clamps and plastic ties used to
hold the brake line(s) in place. Install the brake hose
BRAKE HOSE AND
along its original path. The metal clamps can be re-
LINE REPLACEMENT
used.
3. Cut any plastic ties and discard them.
A combination of steel and flexible brake lines
connect the master cylinder to its brake calipers.
4. On dual disc models, remove the bolt (A, Figure
Banjo fittings and bolts connect brake hoses to the
123) securing the brake hose mounting plate to the
master cylinder and brake calipers. Steel/rubber
lower steering stem. Do not lose the guide plate (B,
washers seal the banjo fittings.
Figure 123) between the hose mounting plate and
Replace a hose if the flexible portion shows
the steering stem.
swelling, cracking or other damage. Likewise, re-
5. Remove the screw or nut securing the metal
place the brake hose if the metal portion leaks or if
clamps around the brake line. Spread the clamp and
there are dents or cracks.
remove it from the brake line.
6. Remove the banjo bolt and washers (A, Figure
124) securing the hose to the brake caliper(s).
Front Brake Hose
7. Remove the banjo bolt and washers securing the
Removal/Installation
hose to the master cylinder (Figure 125).
A combination steel/flexible brake hose (Figure
8. Cover the ends of the brake hose(s) to prevent
122) connects the front master cylinder to the front
brake fluid from leaking out.
490
CHAPTER TWELVE
9. Remove the brake hose(s) (B, Figure 124) from
the motorcycle.
124
10. If the existing brake hose assembly is going to
be reinstalled, inspect it as follows:
a. Check the metal pipe where it enters and exits
at the flexible hose. Check the crimped clamp
for looseness or damage.
b. Check the flexible hose portion for swelling,
cracks or other damage.
c. If any wear or damage is found, replace the
brake hose assembly.
11. Install the brake hose, washers (Figure 122)
and banjo bolts in the reverse order of removal
while noting the following:
125
a. Install new sealing washers against the side of
each hose fitting.
b. Carefully install the clips and guides to hold
the brake hose in place.
c. Tighten the banjo bolts to the specification in
Table 2.
d. Refill the master cylinder with clean brake
fluid clearly marked DOT 5. Bleed the front
brake system as described in this chapter.
WARNING
Do not ride the motorcycle until the
126
REAR BRAKE LINE
front brakes operate correctly with
full hydraulic advantage. If neces-
sary, bleed the brake as described in
this chapter.
Rear Brake Hose
Removal/Installation
A single combination steel and rubber brake hose
(Figure 126) connects the rear master cylinder to
the rear brake caliper. The rear brake switch is in-
stalled in the rear brake hose. When buying a new
hose, compare it to the old hose. Make sure the
length and angle of the steel hose portion is correct.
Install new banjo bolt washers at both hose ends.
CAUTION
Do not spill any brake fluid on the
swing arm, frame or rear wheel.
Wash brake fluid off any painted,
plated or plastic surfaces immedi-
1. Sealing washer
2. Brake line
ately, as it will damage most surfaces
3. Banjo bolt
it contacts. Use soapy water and
rinse completely.
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BRAKES
491
1. Remove the exhaust system as described in
127
Chapter Seven.
2. On models so equipped, remove the right side
saddlebag.
3. Drain the hydraulic brake fluid from the rear
brake system as follows:
a. Connect a hose to the bleed valve. Refer to A,
Figure 127, typical.
b. Insert the loose end of the hose in a container
to catch the brake fluid.
c. Open the caliper bleed valve and operate the
rear brake pedal to pump the fluid out of the
master cylinder and brake line. Continue until
all of the fluid is removed.
128
d. Close the bleed valve and disconnect the
hose.
e. Dispose of this brake fluid—never reuse
brake fluid. Contaminated brake fluid will
cause brake failure.
4. Before removing the brake line, note the brake
line routing from the master cylinder to the caliper.
In addition, note the number and position of the
metal hose clamps and plastic ties used to hold the
brake line in place. Install the brake hose along its
original path. The metal clamp can be reused. How-
ever, new plastic ties will have to be installed.
5. Cut the plastic ties and discard them.
129
6. Remove the bolt and clamp securing the brake
hose to the rear swing arm (Figure 128).
7. Disconnect the electrical connector (A, Figure
12
129) from the rear brake switch.
8. Remove the banjo bolt and washers securing the
hose to the brake caliper. Refer to B, Figure 127,
typical.
9. Remove the banjo bolt and washers (B, Figure
129) securing the hose to the master cylinder.
10. Remove the brake hose from the motorcycle.
11. If the existing brake hose assembly is going to
be reinstalled , inspect it as follows:
a. Check the metal pipe (A, Figure 130) where
130
it enters and exits the flexible hose. Check the
crimped clamp for looseness or damage.
b. Check the flexible hose portion for swelling,
cracks or other damage.
c. If any wear or damage is found, replace the
brake hose.
12. If necessary, remove the stoplight switch (B,
Figure 130) from the rear brake hose fitting. Re-
verse to install the switch. Tighten the switch se-
curely.
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492
CHAPTER TWELVE
131
132
13. Install the brake hose in the reverse order of re-
moval while noting the following:
a. Install new sealing washers against the side of
each hose fitting.
b. Carefully install the clips and guides to hold
the brake hose in place.
c. Tighten the banjo bolts to the specification in
Table 2.
d. Refill the master cylinder with clean brake
133
fluid clearly marked DOT 5. Bleed the rear
brake system as described in this chapter.
WARNING
Do not ride the motorcycle until the
rear brake is operating correctly with
full hydraulic advantage. If neces-
sary, bleed the brake as described in
this chapter.
BRAKE DISC
The brake discs are separate from the wheel hubs
discs are thin, and grinding will only reduce their
and can be removed once the wheel is removed
thickness, causing them to warp quite rapidly. If the
from the motorcycle.
disc is warped, the brake pads may be dragging on
the disc due to a faulty caliper and causing the disc
to overheat. Overheating can also be caused when
Inspection
there is unequal pad pressure on both sides of the
disc.
It is not necessary to remove the disc from the
wheel to inspect it. Small nicks and marks on the
Three main causes of unequal brake pad pressure
disc are not important, but radial scratches deep
are:
enough to snag a fingernail reduce braking effec-
a. The brake caliper piston seals are worn or
tiveness and increase brake pad wear. If these
damaged.
grooves are evident, and the brake pads are wearing
rapidly, the disc should be replaced.
b. The small master cylinder relief port is
The minimum (MIN) disc thickness is stamped
plugged.
on the disc.
When servicing the brake discs, do not have the
c. The primary cup on the master cylinder pis-
discs surfaced to compensate for any warp. The
ton is worn or damaged.
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BRAKES
493
4. Clean the disc of any rust or corrosion and wipe
134
clean with lacquer thinner. Never use an oil-based
solvent that may leave an oil residue on the disc.
Removal/Installation
1. Remove the front or rear wheel as described in
Chapter Nine.
NOTE
On dual disc models, the disc is
marked with a LEFT or RIGHT (Fig-
ure
133). The disc must be rein-
stalled on the correct side of the
135
wheel.
2. Remove the Torx bolts (Figure 134) securing
the brake disc to the hub and remove the disc.
3. Check the brake disc bolts for thread damage.
Replace worn or damaged fasteners.
4. Check the brake disc threaded bolt holes in the
wheel hub for thread damage. Clean out with a tap if
necessary.
5. Clean the disc and the disc mounting surface
thoroughly with brake cleaner or contact cleaner.
Allow the surfaces to dry before installation.
6A. On 1999 models, to install the front brake
NOTE
It
is
not
necessary to
remove
the
disc(s) perform the following:
wheel to
measure the
disc thick-
a. Install the disc onto the correct side of the
ness. The measurement can be per-
wheel hub, aligning the notch in the brake
formed with the wheel installed or
disc with the 1/4 in. (6.3 mm) blind hole in the
12
removed.
hub (Figure 135).
b. Apply a drop of ThreeBond TB1342 or an
equivalent to each bolt thread prior to installa-
1. Measure the thickness of the disc at several lo-
tion.
cations around the disc with a vernier caliper or a
c. Install new Torx bolts and tighten to the speci-
micrometer (Figure 131). The disc must be re-
fication in Table 2.
placed if the thickness in any area is less than the
6B. On 2000-on models, to install the front brake
marked MIN dimension on the disc.
disc(s) perform the following:
2. Make sure the disc mounting bolts are tight prior
a. Install the disc onto the correct side of the
to running this check. Check the disc runout with a
wheel hub.
dial indicator as shown in Figure 132.
b. Apply a drop of ThreeBond TB1342 or an
equivalent to each bolt thread prior to installa-
NOTE
tion.
When checking the front disc, turn the
c. Install new Torx bolts and tighten to the speci-
handlebar all the way to one side,
fication in Table 2.
then to the other side.
7. To install the rear brake disc, perform the follow-
ing:
3. Slowly rotate the wheel and watch the dial indi-
a. Apply a drop of ThreeBond TB1342 or an
cator. If the runout exceeds that listed in Table 1, re-
equivalent to each bolt thread prior to installa-
place the disc(s).
tion.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
494
CHAPTER TWELVE
b. Install new Torx bolts and tighten to the speci-
fication in Table 2.
136
BLEEDING THE SYSTEM
If air enters the brake system, the brake will feel soft
or spongy, greatly reducing braking pressure. If this
happens, the system must be bled to remove the air.
Air can enter the system if there is a leak in the system,
the brake fluid level in a master cylinder runs low, a
brake line is opened, or the brake fluid is replaced.
When bleeding the brakes, two different methods
can be used—with a brake bleeder or manually.
This section describes both procedures separately.
137
Before bleeding the brake system, observe the
following conditions:
1. Check the brake lines to make sure that all fit-
tings are tight.
2. Check that the caliper piston does not stick or
bind in its bore.
3. Check piston movement in each master cylinder.
Operate the lever or brake pedal, making sure there
is no binding or other abnormal conditions present.
Brake Bleeder Process
Leave the cover in place during this procedure to
This procedure uses the Mityvac hydraulic brake
prevent the entry of dirt.
bleeding kit (Figure 136) that is available from au-
tomotive or motorcycle supply stores or from mail
WARNING
order outlets.
Use brake fluid clearly marked DOT 5
from a sealed container. Other types
NOTE
may vaporize and cause brake failure.
This procedure is shown on the rear
Always use the same brand name; do
wheel and relates to the front wheel as
not intermix, as many brands are not
well.
compatible. Do not intermix DOT 3,
DOT 4 or DOT 5.1 brake fluid, as it
1. Remove the dust cap from the caliper bleed
can cause brake component damage
valve.
leading to brake system failure.
2. Place a clean shop cloth (A, Figure 137) over the
caliper to protect it from accidental brake fluid spills.
8. Operate the pump several times to create a vac-
3. Open the bleed screw approximately 1/2 turn (B,
uum in the line. Brake fluid will quickly flow from
Figure 137).
the caliper into the pump’s reservoir. Tighten the
4. Assemble the brake bleeder according to its
caliper bleed valve before the fluid stops flowing
manufacturer’s instructions. Secure it to the caliper
through the hose. To prevent air from being drawn
bleed valve (Figure 138).
through the master cylinder, add fluid to maintain
5. Clean the top of the master cylinder of all debris.
its level at the top of the reservoir.
6. Remove the screws securing the master cylinder
top cover and remove the cover and rubber dia-
NOTE
phragm.
Do not allow the master cylinder res-
7. Fill the reservoir almost to the top with DOT5
ervoir to empty during the bleeding
brake fluid and reinstall the diaphragm and cover.
operation or more air will enter the
-------------------------------------------------------------------------------------------------------------------------------------------------------------
BRAKES
495
correctly with full hydraulic advan-
138
tage.
15. Test ride the motorcycle slowly at first to make
sure that the brakes are operating properly.
Without a Brake Bleeder
NOTE
Before bleeding the brake, check that
all brake hoses and lines are tight.
1. Connect a length of clear tubing to the bleed
system. If this occurs, the procedure
valve on the caliper. Place the other end of the tube
must be repeated.
into a clean container. Fill the container with
enough clean DOT 5 brake fluid to keep the end of
9. Continue the bleeding process until the fluid
the tube submerged. The tube must be long enough
drawn from the caliper is bubble free. If bubbles are
so that a loop can be made higher than the bleeder
withdrawn with the brake fluid, more air is trapped
valve to prevent air from being drawn into the cali-
in the line. Repeat Step 8, making sure to refill the
per during bleeding.
master cylinder to prevent air from being drawn into
2. Clean the top of the master cylinder of all de-
the system.
bris.
10. When the brake fluid is free of bubbles, tighten
3. Remove the screws securing the master cylinder
the bleed valve and remove the brake bleeder as-
top cover. Remove the cover and diaphragm.
sembly. Reinstall the bleed valve dust cap.
4. Fill the reservoir almost to the top with DOT5
brake fluid and reinstall the diaphragm and cover.
NOTE
Leave the cover in place during this procedure to
Dispose of the brake fluid expelled
prevent the entry of dirt.
during the bleeding process. Do not
reuse the brake fluid.
WARNING
Use brake fluid clearly marked DOT
11. If necessary, add fluid to correct the level in the
12
5 from a sealed container. Other
master cylinder reservoir. When topping off the
types may vaporize and cause brake
front master cylinder, turn the handlebar until the
failure. Always use the same brand
reservoir is level; add fluid until it is level with the
name; do not intermix, as many
reservoir gasket surface. The fluid level in the rear
brands are not compatible. Do not
master cylinder must be slightly below the upper
intermix DOT 3, DOT 4 or DOT 5.1
gasket surface.
brake fluid, as it can cause brake
component damage leading to brake
12. On front dual-disc models, repeat steps 1-9 for
system failure.
the other caliper.
13. Reinstall the reservoir diaphragm and cover.
NOTE
Install the screws and tighten securely.
During this procedure, it is important
14. Test the feel of the brake lever or pedal. It must
to check the fluid level in the master
be firm and offer the same resistance each time it is
cylinder reservoir often. If the reser-
operated. If it feels spongy, it is likely that there is
voir runs dry, air will enter the sys-
still air in the system and it must be bled again. After
tem.
bleeding the system, check for leaks and tighten all
5. Slowly apply the brake lever several times. Hold
fittings and connections as necessary.
the lever in the applied position and open the bleed
WARNING
valve about 1/2 turn. Allow the lever to travel to its
Do not ride the motorcycle until the
limit. When the limit is reached, tighten the bleed
front and/or rear brake are operating
valve, then release the brake lever. As the brake
-------------------------------------------------------------------------------------------------------------------------------------------------------------
496
CHAPTER TWELVE
139
REAR BRAKE PEDAL
1. Nut
2. Pushrod
3. Clevis pin
4. Acorn nut
5. Washer
6. Brake pedal
7. Washer
8. Footrest and
brake pedal
bracket
9. Bolt
10. Washer
11. Cotter pin
12. Bolt
13. Pad
FXDWG MODELS*
1. Nut
2. Pushrod
3. Spring washer
4. Brake pedal
5. Snap ring
6. Cotter pin
7. Pivot pin
*For 2003 models
FXDWL, FXDX, FXD, FXDS-CON, FXDXT, AND FXDP MODELS
see Supplement
fluid enters the system, the level will drop in the
NOTE
master cylinder reservoir. Maintain the level at the
Dispose of the brake fluid expelled
top of the reservoir to prevent air from being drawn
during the bleeding process. Do not
reuse the brake fluid.
into the system.
6. Continue the bleeding process until the fluid
8. If necessary, add fluid to correct the level in the
emerging from the hose is completely free of air
master cylinder reservoir. When topping off the
bubbles. If the fluid is being replaced, continue until
front master cylinder, turn the handlebar until the
the fluid emerging from the hose is clean.
reservoir is level; add fluid until it is level with the
reservoir gasket surface. The fluid level in the rear
NOTE
master cylinder must be slightly below the upper
If bleeding is difficult, allow the
gasket surface.
fluid to stabilize for a few hours. Re-
9. On front dual-disc models, repeat steps 1-9 for
peat the bleeding procedure when
the other caliper.
the tiny bubbles in the system settle
10. Install the diaphragm and top cover and tighten
out.
the screws securely.
11. Test the feel of the brake lever or pedal. It must
7. Hold the lever in the applied position and tighten
be firm and offer the same resistance each time it is
the bleed valve. Remove the bleed tube and install
operated. If it feels spongy, it is likely that there is
the bleed valve dust cap.
still air in the system and it must be bled again. After
-------------------------------------------------------------------------------------------------------------------------------------------------------------
BRAKES
497
1. Remove the exhaust system as described in
140
Chapter Seven.
2. Remove the bolts (A, Figure 140) securing the
brake pedal bracket to the frame.
3. Remove the bracket (B, Figure 140) and pedal
assembly.
4. Disconnect the push rod from the pedal assembly.
5A. On FXDWG models, remove the bolt, washers
and acorn nut securing the pedal to the mounting
bracket. Remove the pedal.
5B. On all models except FXDWG models, remove
the snap ring securing the pedal to the mounting
bracket. Remove the pedal.
bleeding the system, check for leaks and tighten all
6. Inspect the brake pedal for fractures or damage
fittings and connections as necessary.
and replace if necessary.
7. On FXDWG models, perform the following:
WARNING
a. Inspect the bushing within the pedal for wear.
Do not ride the motorcycle until the
Replace if necessary.
front and/or rear brake are operating
b. Inspect the shoulder on the bracket where the
correctly with full hydraulic advan-
tage.
pedal rides for wear.
c. Lubricate the bushing and bracket shoulder
12. Test ride the motorcycle slowly at first to make
with waterproof grease.
sure that the brakes are operating properly.
8. Install the pedal by reversing these removal
steps while noting the following:
a. Tighten the special bolt securely.
REAR BRAKE PEDAL
b. Install a new cotter pin and bend the ends over
completely.
Removal/Lubrication/Installation
c. Adjust the rear brake pedal height as de-
Refer to Figure 139.
scribed in Chapter Three.
12
Table 1 BRAKE SYSTEM SPECIFICATIONS
Brake fluid
DOT 5 silicone base
Brake pad minimum thickness
1999 models
1/16 in. (1.6 mm)
2000 and later
0.04 in. (1.02 mm)
Brake disc
Thickness
Stamped on disc
Runout
0.008 in. (0.20 mm)
Table 2 BRAKE SYSTEM TORQUE SPECIFICATIONS
Item
ft.-lb.
in.-lb.
N·m
Bleed valves
-
80-100
9-11
Caliper bridge bolts
(front and rear)
28-38
-
38-51
Brake disc bolts
Front wheel
16-24
-
22-32
Rear wheel
30-45
-
41-61
Brake pad pins (2000-on)
Front and rear calipers
-
180-200
20-23
(continued)
-------------------------------------------------------------------------------------------------------------------------------------------------------------
498
CHAPTER TWELVE
Table 2 BRAKE SYSTEM TORQUE SPECIFICATIONS (continued)
Item
ft.-lb.
in.-lb.
N·m
Front brake caliper (1999)
Inner brake pad
retainer screw
-
40-50
5-6
Upper mounting bolt
25-30
-
34-41
Lower mounting pin
25-30
-
34-41
Front master cylinder
Clamp screw
-
70-80
8-9
Cover screws
-
6-8
1
Rear brake caliper (1999)
Brake pad pins
15-20
-
20-27
Rear master cylinder
Mounting nut
40-50
-
54-68
Cover screws
-
6-8
1
Brake line banjo bolts
17-22
-
23-30
-------------------------------------------------------------------------------------------------------------------------------------------------------------
CHAPTER THIRTEEN
BODY
13
SEAT
6. Make sure the nylon retaining clip is in place,
then install the bolt securing the rear of the seat to
Removal/Installation
the fender bracket. Tighten the bolt securely.
7. Pull up on the front of the seat to ensure the seat
1. Remove the bolt (A, Figure 1) securing the rear
front hook is secured in place on the frame bracket.
of the seat to the fender bracket. Do not lose the ny-
lon retaining clip between the bracket and the rear
WINDSHIELD
fender.
2. Pull the seat toward the rear to release the seat
Removal/Installation
front hook from the frame bracket.
(FXDS-CONV)
3. Carefully slide the seat forward and out of the
1. Place the motorcycle on level ground on the jiffy
seat strap (B, Figure 1). Remove the seat.
stand.
4. Install the strap under the seat.
2. Loosen, but do not remove, the two screws on
5. Slide the seat forward and insert the front hook
each side securing the windshield and bracket to the
under the frame bracket (Figure 2).
mounting brackets on the forks.
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