| | | ------------------------------------------------------------------------------------------------------------------------------------------------------------- 460 CHAPTER TWELVE 8. Inspect the cylinder wall and piston (Figure 26) for scratches, scoring or other damage. 26 Assembly 1. The following parts are included in a H-D re- build kit (part No. 44020-83): piston seal (A, Fig- ure 27), piston (B), dust boot (C) and retaining ring (D). NOTE Never reuse an old dust boot or piston seal. Very minor damage or age dete- rioration can make the boot and seal useless. 27 2. Soak the new dust and piston seal in clean DOT5 brake fluid. 3. Carefully install the new piston seal into the groove. Make sure the seal is properly seated in its groove. 4. Install new O-rings into the caliper grooves. 5. Wipe the inside of the pin boot with Dow Corning MOLY 44 grease. Then insert the boot into the bushing bore with the boots flange end seating in the bore groove (Figure 28). 6. Insert the threaded bushing into the boot (Figure 28 29). 7. Install the piston dust boot on the piston before the piston is installed in the caliper bore. Perform the following: a. Place the piston on the workbench with its open side facing up. b. Align the piston dust boot with the piston so that the shoulder on the dust boot faces up. c. Slide the piston dust boot onto the piston until the inner lip on the dust boot seats in the pis- ton groove (Figure 22). 8. Coat the piston and the caliper bore with DOT 5 brake fluid. 29 9. Align the piston with the caliper bore so that its open end faces out (Figure 22). Then push the pis- ton in until it bottoms. 10. Seat the piston dust boot (Figure 30) into the caliper bore. 11. Locate the retaining ring groove in the top end of the caliper bore. Align the retaining ring so that its gap (Figure 31) is at the top of the caliper bore and install the ring into the ring groove. Make sure the retaining ring is correctly seated in the groove. ------------------------------------------------------------------------------------------------------------------------------------------------------------- BRAKES 461 15. Bleed the brake as described under Bleeding 30 the System in this chapter. FRONT BRAKE CALIPER (2000-ON MODELS) Removal/Installation CAUTION Do not spill any brake fluid on the front fork or front wheel. Wash brake fluid off any painted, plated or plastic surfaces or plastic parts immediately, as it will destroy most surfaces it con- 31 tacts. Use soapy water and rinse com- pletely. Align gap with top of caliper bore 1. If the caliper assembly is going to be disassem- bled for service, perform the following: NOTE By performing Steps 1a and 1b, com- pressed air may not be necessary for Retaining piston removal during caliper disas- ring sembly. a. Remove the brake pads as described in this chapter. CAUTION Do not allow the pistons to travel out 12 far enough to come in contact with the brake disc. If this happens, the pistons may scratch or gouge the disc during 32 caliper removal. b. Slowly apply the brake lever to push the pis- tons part way out of the caliper assembly for ease of removal during caliper service. c. Loosen the two body mounting bolts (A, Fig- ure 32). d. Loosen the brake hose banjo bolt (B, Figure 32). 2. Remove the banjo bolt and sealing washers (B, Figure 32) attaching the brake hose to the caliper 12. Apply a light coat of Dow Corning MOLY 44 assembly. Do not lose the sealing washer on each grease to the caliper mounting lug bores. side of the hose fitting(s). 13. If removed, install the bleed screw assembly 3. Place the loose end of the brake hose in a and tighten to the specification in Table 2. reclosable plastic bag to prevent the entry of foreign 14. Install the caliper and brake pads as described matter and prevent any residual brake fluid from in this chapter. leaking out. ------------------------------------------------------------------------------------------------------------------------------------------------------------- 462 CHAPTER TWELVE 4. Remove the bolts (Figure 33) securing the brake caliper assembly to the front fork and remove the 33 caliper. 5. If necessary, disassemble and service the caliper assembly as described in this chapter. 6. Install by reversing these removal steps while noting the following: a. Carefully install the caliper assembly onto the disc, being careful not to damage the leading edge of the brake pads. b. Install the bolts (Figure 33) securing the brake caliper assembly to the front fork and tighten to the specifications in Table 2. 4. Place a piece of soft wood or folded shop cloth c. Apply clean DOT 5 brake fluid to the rubber over the end of the pistons and the caliper body. portions of the new sealing washers prior to Turn this assembly over with the pistons facing installation. down. d. Install a new sealing washer on each side of 5. Perform this step over and close to a workbench the brake hose fitting and install the banjo top. bolt (B, Figure 32). Tighten the banjo bolt to the specification in Table 2. WARNING Compressed air will force the pistons e. Bleed the brake as described under Bleeding out of the caliper bodies under con- the System in this chapter. siderable force. Do not block the pis- ton by hand, as injury will result. WARNING Do not ride the motorcycle until the 6. Apply the air pressure in short spurts to the hy- front brakes operate correctly with draulic fluid passageway and force out the pistons. full hydraulic advantage. If neces- Repeat for the other caliper body half. Use a service sary, bleed the brake as described in this chapter. station air hose if compressed air is not available. CAUTION Disassembly In the following step, do not use a sharp tool to remove the dust and pis- ton seals from the caliper cylinders. Refer to Figure 34. Do not damage the cylinder surface. 1. Remove the caliper and brake pads as described in this chapter. 7. Use a piece of wood or plastic scraper and care- 2. Remove the two caliper body bolts (Figure 35) fully push the dust seal and the piston seal (Figure loosened during the removal procedure. 37) in toward the caliper cylinder and out of their 3. Separate the caliper body halves. Remove the grooves. Remove the dust and piston seals. O-ring seals (Figure 36). New O-ring seals must be 8. If necessary, unscrew and remove the bleed installed every time the caliper is disassembled. valve (A, Figure 38). 9. Inspect the caliper assembly as described in this NOTE section. If the pistons were partially forced out of the caliper body during removal, steps 4-6 may not be necessary. If the Inspection pistons or caliper bores are corroded or very dirty, a small amount of com- pressed air may be necessary to com- 1. Clean both caliper body halves and pistons in pletely remove the pistons from the clean DOT 5 brake fluid or isopropyl alcohol and body bores. dry with compressed air. ------------------------------------------------------------------------------------------------------------------------------------------------------------- BRAKES 463 34 FRONT BRAKE CALIPER (2000-ON) 1. Inboard caliper 9. Outboard caliper body body 2. O-rings 10. Cap 3. Piston seal 11. Mounting bolt 4. Dust seal 12. Bleed valve 5. Piston 13. Pad pin bolt 6. Inboard brake pad 14. Trim plate 7. Anti-rattle spring 15. Mounting bolt 8. Outboard brake pad 35 37 12 36 38 ------------------------------------------------------------------------------------------------------------------------------------------------------------- 464 CHAPTER TWELVE 2. Make sure the fluid passageways (Figure 39) in the piston bores are clear. Apply compressed air to 39 the openings to make sure they are clear. Clean out, if necessary, with clean brake fluid. 3. Make sure the fluid passageways (A, Figure 40) in both caliper body halves are clear. Apply com- pressed air to the openings to make sure they are clear. Clean out, if necessary, with clean brake fluid. 4. Inspect the piston and dust seal grooves (Figure 41) in both caliper bodies for damage. If damaged or corroded, replace the caliper assembly. 5. Inspect the banjo bolt threaded hole (B, Figure 38) in the outboard caliper body. If worn or dam- aged, clean out with a metric thread tap or replace the caliper assembly. 40 6. Inspect the bleed valve threaded hole in the cali- per body. If worn or damaged, clean out with a met- ric thread tap or replace the caliper assembly. 7. Inspect the bleed valve. Apply compressed air to the opening and make sure it is clear. Clean out, if necessary, with clean brake fluid. Install the bleed screw and tighten to the specification in Table 2. 8. Inspect both caliper bodies for damage. Check the inboard caliper mounting bolt hole threads (B, Figure 40) for wear or damage. Clean up with an appropriately sized metric tap or replace the caliper assembly. 9. Inspect the cylinder walls and pistons for 41 scratches, scoring or other damage. 10. Check the anti-rattle spring (Figure 42) for wear or damage. Assembly NOTE Never reuse old dust seals or piston seals. Very minor damage or age dete- rioration can make the seals useless. 1. Soak the new dust and piston seals in clean DOT5 brake fluid. 42 2. Coat the piston bores and pistons with clean DOT5 brake fluid. 3. Carefully install the new piston seals into the lower grooves. Make sure the seals are properly seated in their respective grooves. 4. Carefully install the new dust seals into the up- per grooves. Make sure all seals are properly seated in their respective grooves (Figure 43). 5. Repeat Step 3 and Step 4 for the other caliper body half. ------------------------------------------------------------------------------------------------------------------------------------------------------------- BRAKES 465 6. Position the pistons with the open end facing out 43 and install the pistons into the caliper cylinders (A, Figure 44). Push the pistons in until they bottom (B, Figure 44). 7. Repeat Step 6 for the other caliper body half. Make sure all pistons are installed correctly. 8. Coat the new O-ring seals in DOT5 brake fluid and install the O-rings (Figure 36) into the inboard caliper half. 9. Install the anti-rattle spring (Figure 45) onto the boss on the outboard caliper half. 10. Make sure the O-rings are still in place and as- semble the caliper body halves. 11. Install one of the caliper mounting bolts 44 through the upper hole (A, Figure 46) to correctly align the caliper halves. 12. Install the two caliper body bolts (B, Figure 46) and tighten securely. They will be tightened to the specification after the caliper is installed on the front fork. 13. If removed, install the bleed valve assembly and tighten to the specification in Table 2. 14. Install the caliper and brake pads as described in this chapter. 15. Tighten the two caliper body mounting bolts (A, Figure 32) to the specification in Table 2. 45 16. Bleed the brake as described under Bleeding the System in this chapter. 12 FRONT MASTER CYLINDER Removal CAUTION Cover the fuel tank and front fairing with a heavy cloth or plastic tarp to protect them from accidental brake fluid spills. Wash brake fluid off any painted, plated or plastic surfaces im- 46 mediately, as it will damage most sur- faces it contacts. Use soapy water and rinse completely. 1. Clean the top of the master cylinder of all debris. 2. Remove the screws (A, Figure 47) securing the top cover. 3. Remove the top cover (B, Figure 47) and dia- phragm from the master cylinder reservoir. 4. Use a shop syringe and draw all of the brake fluid out of the master cylinder reservoir. Tempo- ------------------------------------------------------------------------------------------------------------------------------------------------------------- 466 CHAPTER TWELVE rarily reinstall the diaphragm and the cover. Tighten the screws finger-tight. 47 5. On models so equipped, remove the windshield or front fairing. 6. Loosen and remove the mirror (A, Figure 48) from the master cylinder. 7. On models so equipped, remove the front turn signal assembly (B, Figure 48) from the master cyl- inder. CAUTION Failure to install the spacer in Step 8 will result in damage to the rubber boot and plunger on the front brake switch. 48 8. Insert a 5/32 in. (4 mm) thick spacer (A, Figure 49) between the brake lever and lever bracket. Make sure the spacer stays in place during the fol- lowing steps. 9. Remove the banjo bolt and sealing washers (B, Figure 49) securing the brake hose to the master cylinder. 10. Place the loose end of the brake hose in a reclosable plastic bag to prevent the entry of mois- ture and debris. Tie the loose end of the hose up to the handlebar. 11. Remove the screw securing the right side 49 switch together and separate the switch (A, Figure 50). 12. Remove the T27 Torx bolts and washers (B, Figure 50) securing the clamp and master cylinder to the handlebar. 13. Remove the master cylinder assembly (C, Fig- ure 49) from the handlebar. 14. Drain any residual brake fluid from the master cylinder and dispose of properly. 15. If the master cylinder assembly is not going to be serviced, reinstall the clamp and Torx bolts to the master cylinder. Place the assembly in a reclosable 50 plastic bag to protect it from foreign matter. Installation 1. If not in place, insert the 5/32 in. (4 mm) thick spacer (A, Figure 49) between the brake lever and lever bracket. Make sure the spacer stays in place during the following steps. 2. Position the front master cylinder onto the han- dlebar. Align the master cylinder notch (A, Figure ------------------------------------------------------------------------------------------------------------------------------------------------------------- BRAKES 467 (B, Figure 53) into place. Install the switch’s 51 clamping screw and tighten securely. 4. Position the clamp and install the clamping Torx bolts and washers (B, Figure 50). Tighten the upper mounting bolt first, then the lower bolt. Tighten the bolts to the specification in Table 2. 5. Apply clean DOT 5 brake fluid to the rubber por- tions of the new sealing washers prior to installa- tion. 6. Install new sealing washers and the banjo bolt (B, Figure 49) securing the brake hose to the master cylinder. Tighten the banjo bolt to the specification in Table 2. 7. Remove the spacer (A, Figure 49) from the 52 brake lever. 8. On models so equipped, install the front turn sig- nal assembly (B, Figure 48) onto the master cylin- der. Aim the lens in the same direction as the one on the left side. 9. Install the mirror (A, Figure 48) onto the master cylinder. Correctly adjust the mirror. 10. On models so equipped, install the windshield or front fairing. 11. Temporarily install the diaphragm and top cover (B, Figure 47) onto the reservoir. Tighten the screws finger-tight at this time. 12. Refill the master cylinder reservoir and bleed 53 the brake system as described under Bleeding the System in this chapter. 12 Disassembly Refer to Figure 54. 1. Store the master cylinder components in a di- vided container, such as a restaurant-size egg car- ton, to help maintain their correct alignment position. 2. If still in place, remove the screws securing the 51) with the locating tab (B, Figure 51) on the top cover. Remove the top cover and the diaphragm lower portion of the right side switch. from the master cylinder. 3. Remove the master cylinder assembly as de- CAUTION scribed in this chapter. Do not damage the front brake light 4. Remove the snap ring (A, Figure 55) and pivot switch and rubber boot (Figure 52) pin securing the hand lever to the master cylinder. when installing the master cylinder in Remove the hand lever (B, Figure 55). Step 3. 5. Remove the retainer (A, Figure 56) and the rub- ber boot (B, Figure 56) from the area where the 3. Push the master cylinder all the way onto the hand lever actuates the piston assembly. handlebar (A, Figure 53), hold it in this position 6. Remove the piston assembly (Figure 57) and the and install the upper portion of the right side switch spring. ------------------------------------------------------------------------------------------------------------------------------------------------------------- 468 CHAPTER TWELVE 54 FRONT MASTER CYLINDER 1. Screw 2. Sight glass 3. Top cover 4. Diaphragm 5. Pivot pin 6. T27 Torx screw 7. Washer 8. Clamp 9. Body 10. Piston assembly 11. Bushing 12. Hand lever 13. Snap ring 14. Washer 15. Acorn nut 55 56 7. Inspect all parts as described in this section. 57 Inspection Replace worn or damage parts as described in this section. It is recommended that a new piston kit as- sembly be installed every time the master cylinder is disassembled. 1. Clean all parts in isopropyl alcohol or clean DOT5 brake fluid. Inspect the body cylinder bore surface for signs of wear and damage. If less than ------------------------------------------------------------------------------------------------------------------------------------------------------------- BRAKES 469 58 62 perfect, replace the master cylinder assembly. The 59 body cannot be replaced separately. 2. Inspect the piston cup (A, Figure 58) and O-ring (B) for signs of wear and damage. 3. Make sure the fluid passage (Figure 59) in the bottom of the master cylinder reservoir is clear. Clean out if necessary. 4. Inspect the piston contact surface for signs of wear and damage. 5. Check the end of the piston (C, Figure 58) for wear caused by the hand lever. 6. Check the hand lever pivot lugs in the master cylinder body for cracks or elongation. 7. Inspect the hand lever pivot hole and bushing (A, 60 Figure 60) and the pivot pin (B) for wear, cracks or elongation. 8. Inspect the piston cap and retainer (Figure 61) for wear or damage. 12 9. Inspect the threads in the bore for the banjo bolt. If worn or damaged, clean out with a thread tap or replace the master cylinder assembly. 10. Check the top cover and diaphragm for damage and deterioration. 11. If necessary, separate the cover from the dia- phragm as follows: a. Pull straight up on the sight glass (Figure 62) and remove it from the cover and diaphragm. 61 b. Separate the diaphragm from the cover. c. The trim plate may separate from the cover. Assembly NOTE If installing a new piston assembly, coat all parts with the lubricant pro- vided in the new H-D parts kit instead of using DOT5 brake fluid. If install- ------------------------------------------------------------------------------------------------------------------------------------------------------------- 470 CHAPTER TWELVE ing existing parts, coat them with DOT5 brake fluid. 63 NOTE Be sure to purchase the correct new piston parts kit for the specific motor- cycle being worked on. The piston bore diameter is larger on models equipped with dual front discs. The parts for the two different master cyl- inders are not interchangeable. NOTE The cover and diaphragm must be as- sembled as follows. If the sight glass is not installed correctly through the 64 cover and diaphragm neck, brake fluid will leak past these components. 1. If disassembled, assemble the cover and the dia- phragm as follows: a. If removed, install the trim plate (Figure 63) onto the cover. b. Insert the neck of the diaphragm into the cover. Press it in until it seats correctly and the outer edges are aligned with the cover. c. Push the sight glass (Figure 62) straight down through the cover and the neck of the diaphragm (Figure 64) until it snaps into 65 place. The sight glass must lock these two parts together to avoid a brake fluid leak. 2. Soak the new cup and O-ring and piston assem- bly in clean DOT5 brake fluid for at least 15 min- utes to make them pliable. Coat the inside of the cylinder bore with clean brake fluid prior to the as- sembly of parts. CAUTION When installing the piston assembly, do not allow the cup to turn inside out as it will be damaged and allow brake fluid leakage within the cylinder bore. 66 3A. On 1999 and 2000 models, position the flared end of the spring so it enters the master cylinder first. 3B. On 2001 models, position the metal tab end of the spring (Figure 65) so it enters the master cylinder first. 4. Install the spring and piston assembly into the cylinder (Figure 66). Push them in until they bot- tom in the cylinder (Figure 57). 5. Position the retainer with the flat side going on first and install the piston cap and retainer onto the piston end. ------------------------------------------------------------------------------------------------------------------------------------------------------------- BRAKES 471 REAR BRAKE PAD REPLACEMENT 67 (1999 MODELS) There is no recommended mileage interval for changing the brake pads. Pad wear depends greatly on riding habits and conditions. Frequently check the pads for wear. After removal, measure the thick- ness of each brake pad with a vernier caliper or ruler and compare to the dimensions in Table 1. To maintain an even brake pressure on the disc, al- ways replace both pads in the caliper at the same time. CAUTION Check the pads more frequently when 68 the lining approaches the pad metal backing plate. If pad wear happens to be uneven for some reason, the back- ing plate may come in contact with the disc and cause damage. 1. Read the Brake Service information in this chapter. 2. Park the motorcycle on level ground. 3. Tie the end of the brake pedal up to the frame. If the brake pedal is inadvertently applied, this will pre- vent the piston from being forced out of the cylinder. 4. On models so equipped, remove the right side saddlebag. 69 5. Clean the top of the master cylinder of all debris. 6. Remove the screws securing the cover (Figure 68) and remove the cover and diaphragm. 7. Use a shop syringe and remove about 50 percent 12 of the brake fluid from the reservoir. This will pre- vent the master cylinder from overflowing when the pistons are compressed for reinstallation. Do not drain more than 50 percent of the brake fluid or air will enter the system. Discard the brake fluid. CAUTION Do not allow the master cylinder to 6. Push down on the piston cap (Figure 67), hold it overflow when performing Step 7. there and press the retainer down until it correctly Wash brake fluid off any painted, plated or plastic surfaces immedi- seats in the cylinder groove (A, Figure 56). ately, as it will damage most surfaces 7. Make sure the bushing is in place in the hand le- it contacts. Use soapy water and rinse ver pivot area. completely. 8. Install the hand lever (B, Figure 55) into the master cylinder, install the pivot pin and secure it 8. Loosen both pad pin bolts (A, Figure 69). with the snap ring. Make sure the snap ring is cor- rectly seated in the pivot pin groove (A, Figure 55). CAUTION 9. Slowly apply the lever to make sure it pivots freely. The brake disc is thin and easily dam- 10. Install the master cylinder as described in this aged. When pushing against the disc chapter. in the following step, support the disc ------------------------------------------------------------------------------------------------------------------------------------------------------------- 472 CHAPTER TWELVE adjacent to the caliper to prevent damage. 70 9. Hold the caliper body from the outside and push it toward the brake disc. This will push the piston into the caliper bore to make room for the new brake pads. Constantly check the reservoir to make sure brake fluid does not overflow. Remove fluid, if nec- essary, prior to it overflowing. Install the diaphragm and cover. Tighten the screws finger-tight. 10. Remove the two caliper pin bolts (A, Figure 69) and lift the caliper (B, Figure 69) off the mount- ing bracket. Do not disconnect the brake hose from the caliper. Support the caliper with a piece of heavy wire. 71 11. Lift and then pull the retainer clip (Figure 70) over the mounting bracket and remove it. NOTE If the pads are to be reused, mark them so they will be reinstalled in their original locations. 12. Slide the outboard brake pad (A, Figure 71) off the mounting bracket. 13. Slide the inboard brake pad (B, Figure 71) to- ward the wheel and off the mounting bracket. 14. Remove both pad shims (Figure 72) from the 72 mounting bracket. 15. Check the brake pads for wear or damage. Mea- sure the thickness of the brake pad friction material. Replace the brake pads if they are worn to the ser- vice limit listed in Table 1. Replace both pads as a set. 16. Clean the pad shims and check for cracks or damage. 17. Clean the pad shim mounting areas on the mounting bracket. 18. Check the retainer clip for rust, cracks or other damage. 19. Inspect the caliper pin bolts for cracks, corro- 73 sion or other damage. Replace if necessary. 20. Check the piston dust boot (Figure 73) for damage. Remove and overhaul the caliper if the boot is swollen or damaged or if brake fluid is leak- ing from the caliper. Refer to Rear Brake Caliper (1999 Models) in this chapter. 21. Check the brake disc for wear. 22. Install the pad shims so that their retaining loops face against the outer caliper mounting bracket rails, as shown in Figure 72. ------------------------------------------------------------------------------------------------------------------------------------------------------------- BRAKES 473 26. Insert the retainer clip into the two large holes 74 (Figure 76) in the back of the caliper mounting bracket. Then swing the retainer clip over the top of the brake pads and snap it in place against the outer brake pad (Figure 70). CAUTION The brake pads must seat against both pad shims evenly (Figure 70). If not, the rear brake will drag, causing un- even pad wear and caliper bracket damage. NOTE When installing the caliper over the 75 brake pads, do not dislodge the brake pads and pad shims. 27. Slide the caliper (B, Figure 69) over the brake pads. Install the two pad pin bolts (A, Figure 69) and tighten to the specificationin Table 2. 28. Check to make sure there is sufficient brake fluid in the master cylinder reservoir. Top off if nec- essary. 29. Untie the brake pedal from the frame and pump the rear brake pedal to reposition the brake pads against the brake disc. Roll the motorcycle back and forth and continue to pump the brake pedal as many 76 times as it takes to refill the cylinder in the caliper and correctly locate the brake pads against the disc. NOTE 12 To control the flow of hydraulic fluid, punch a small hole into the seal of a new container of hydraulic (brake) fluid next to the edge of the pour spout. This will help eliminate fluid spillage, especially while adding fluid to the very small reservoir. WARNING 23. Slide the outboard brake pad (Figure 74) over Use brake fluid clearly marked DOT 5 the pad shims and against the outer brake disc sur- from a sealed container. Other types may vaporize and cause brake failure. face. Always use the same brand name; do 24. Slide the inboard brake pad (Figure 75) over the not intermix, as many brands are not pad shims and against the inner brake disc surface. compatible. Do not intermix DOT 3, 25. Check that the pad shims did not move out of DOT4 or DOT5.1 brake fluid, as it position. can cause brake component damage, leading to brake system failure. NOTE Figure 76 shows the caliper mounting 30. Refill the master cylinder reservoir, if neces- bracket removed to better illustrate sary, to maintain the correct fluid level as indicated the step. on the side of the reservoir. Install the diaphragm ------------------------------------------------------------------------------------------------------------------------------------------------------------- 474 CHAPTER TWELVE and the top cover. Tighten the screws to the specifi- cation in Table 2. 77 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. 31. On models so equipped, install the right side saddlebag. REAR BRAKE PAD REPLACEMENT (2000-2001 MODELS) 78 There is no recommended mileage interval for changing the brake pads. Pad wear depends greatly on riding habits and conditions. Frequently check the pads for wear. Increase the inspection interval when the wear indicator reaches the edge of the brake disc. After removal, measure the thickness of each brake pad with a vernier caliper or ruler and compare to the dimensions listed in Table 1. To maintain an even brake pressure on the disc, always replace both pads in the caliper at the same time. Do not disconnect the hydraulic brake hose pistons are compressed for reinstallation. Do not from the brake caliper for brake pad replacement, drain more than 50 percent of the brake fluid or air disconnect the hose only if the caliper assembly is will enter the system. Discard the brake fluid. going to be removed. CAUTION CAUTION Do not allow the master cylinder to Check the pads more frequently when overflow when performing Step 7. the lining approaches the pad metal Wash brake fluid off any painted, backing plate. If pad wear happens to plated or plastic surfaces immedi- be uneven for some reason, the back- ately, as it will damage most surfaces ing plate may come in contact with the it contacts. Use soapy water and rinse disc and cause damage. completely. 1. Read the Brake Service section in this chapter. 8. Loosen the pad pin bolts (Figure 77). 2. Park the motorcycle on level ground. 3. Tie the end of the brake pedal to the frame. If the CAUTION The brake disc is thin and easily dam- brake pedal is inadvertently applied, this will prevent aged. When pushing against the disc the pistons from being forced out of the cylinders. in the following step, support the disc 4. On models so equipped, remove the right side adjacent to the caliper to prevent saddlebag. damage. 5. Clean the top of the master cylinder of all debris. 6. Remove the screws securing the cover and re- 9. Hold the caliper body from the outside and push move the cover (Figure 68) and diaphragm. it toward the brake disc. This will push the outer pis- 7. Use a shop syringe and remove about 50 percent tons into the caliper bores to make room for the new of the brake fluid from the reservoir. This will pre- brake pads. Constantly check the reservoir to make vent the master cylinder from overflowing when the sure brake fluid does not overflow. Remove fluid, if ------------------------------------------------------------------------------------------------------------------------------------------------------------- BRAKES 475 14. Thoroughly clean the pad pins of any corrosion 79 or debris. 15. Check the friction surface of the new pads for any debris or manufacturing residue. If necessary, clean off with an aerosol brake cleaner. NOTE When purchasing new pads, check with the dealer to make sure the fric- tion compound of the new pad is com- patible with the disc material. Remove any roughness from the backs of the new pads with a fine-cut file, then thoroughly clean off. 80 NOTE The brake pads are not symmetrical. The pad with one tab (A, Figure 78) must be installed on the outboard side. The pad with two tabs (B, Figure 78) must be installed on the inboard side of the caliper. 16. Install the outboard pad (Figure 79) into the caliper. 17. Hold the pad in place and install the pad pin bolts (Figure 80) part way in to hold the outboard pad in place. 18. Install the inboard pad (Figure 81) into the cal- 81 iper. 19. Push the pad pin bolts through the inboard pad (Figure 77) and tighten to the specification in Table 2. 20. Check to make sure there is sufficient brake fluid 12 in the master cylinder reservoir. Top off if necessary. 21. Untie the brake pedal from the frame and pump the rear brake pedal to reposition the brake pads against the brake disc. Roll the motorcycle back and forth and continue to pump the brake pedal as many times as it takes to refill the cylin- ders in the calipers and correctly locate the brake pads against the disc. necessary, prior to it overflowing. Install the dia- phragm and cover. Tighten the screws finger-tight. NOTE To control the flow of hydraulic fluid, 10. Remove the pad pin bolts (Figure 77). punch a small hole into the seal of a 11. Remove the inboard and outboard brake pads new container of hydraulic (brake) from the caliper. fluid next to the edge of the pour 12. Check the brake pads for wear or damage. Mea- spout. This will help eliminate fluid sure the thickness of the brake pad friction material. spillage, especially while adding fluid to the very small reservoir. Replace the brake pads if they are worn to the ser- vice limit listed in Table 1. WARNING 13. Carefully remove any rust or corrosion from Use brake fluid clearly marked DOT 5 the disc. from a sealed container. Other types ------------------------------------------------------------------------------------------------------------------------------------------------------------- 476 CHAPTER TWELVE may vaporize and cause brake failure. Always use the same brand name; do 82 not intermix, as many brands are not compatible. Do not intermix DOT 3, DOT 4 or DOT 5.1 brake fluid, as it can cause brake component damage leading to brake system failure. 22. Refill the master cylinder reservoir, if neces- sary, to maintain the correct fluid level as indicated on the side of the reservoir. Install the diaphragm and the top cover. Tighten the screws to the specifi- cation in Table 2. WARNING 83 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. REAR BRAKE CALIPER (1999 MODELS) Removal/Installation 1. If the caliper assembly is going to be disassem- NOTE bled for service, perform the following: If the piston did not come out, remove it as described under Disassembly in NOTE this section. By performing Steps 1a-1e, com- pressed air may not be necessary for 2. Remove the banjo bolt (B, Figure 82) and seal- piston removal during caliper disas- ing washers attaching the brake hose to the caliper sembly. assembly. 3. To remove the rear caliper mounting bracket, re- a. Remove the caliper pad pin bolts (A, Figure fer to Rear Wheel Removal in Chapter Eleven. 82) and remove the caliper from the caliper 4. Install by reversing these removal steps while mounting bracket and the brake pads. noting the following: b. Insert a small screwdriver into the notched a. If removed, install the piston assembly as de- groove machined in the bottom of the piston scribed in this chapter. bore (A, Figure 83). Then pry the retaining ring (A, Figure 83) out of the caliper body. b. If removed, install the brake pads as de- c. Wrap a large cloth around the brake caliper. scribed in this chapter. d. Hold the caliper away from the piston/brake c. Carefully install the caliper assembly onto the pad area. brake pads. e. Operate the rear brake pedal to force the pis- d. Install the bolts (A, Figure 82) securing the ton part way out of the caliper. Do not com- brake caliper assembly and tighten to the pletely remove the piston until after it is torque specifications listed in Table 2. removed for disassembly. Leaving the piston e. Apply clean DOT 5 brake fluid to the rubber partially in the bore helps prevent brake fluid portions of the new sealing washers prior to from spilling out. installation. ------------------------------------------------------------------------------------------------------------------------------------------------------------- BRAKES 477 84 REAR BRAKE CALIPER (1999) 12 1. Retaining ring 8. Pad pin bolt 2. Dust boot 9. Retaining clip 3. Piston 10. Mounting bracket 4. Piston seal 11. Bumper 5. Cap 12. Rubber boot 6. Bleed valve 13. Brake pads 7. Body 14. Shim f. Install a new sealing washer on each side of sary, bleed the brake as described in the brake hose fitting and install the banjo this chapter. bolt (B, Figure 82). Tighten the banjo bolt to the specification in Table 2. Disassembly g. Bleed the brake as described under Bleeding Refer to Figure 84. the System in this chapter. 1. Remove the brake caliper as described in this chapter. WARNING Do not ride the motorcycle until the NOTE rear brake is operating correctly with If the piston was partially forced out full hydraulic advantage. If neces- of the caliper body during removal, ------------------------------------------------------------------------------------------------------------------------------------------------------------- 478 CHAPTER TWELVE 85 86 Steps 2-4 may not be necessary. If the piston or caliper bore is corroded or very dirty, a small amount of com- 1. Wooden block 4. Air hose 2. Rag 5. Caliper pressed air may be necessary to com- 3. Piston pletely remove the piston from the body bore. 2. Insert a screwdriver into the caliper body notched groove (A, Figure 83) and pry the retaining 87 ring out of the groove (Figure 85). 3. Place a piece of soft wood or folded shop cloth over the end of the piston and the caliper body (Fig- ure 86). Turn this assembly over with the piston facing down. WARNING Compressed air will force the piston out of the caliper bodies under con- siderable force. Do not block the pis- ton by hand, as injury will result. 4. Apply the air pressure in short spurts to the hy- 88 draulic fluid passageway and force out the piston. Use a service station air hose if compressed air is not available. 5. Remove the piston and dust boot assembly (Fig- ure 87). 6. Remove the piston seal (Figure 88) from the groove in the caliper body. Inspection Service specifications for the caliper components 2. Inspect the hydraulic fluid passageway in the are not available (except brake pads). Replace any cylinder bore. Make sure it is clean and open. Clean worn, damaged or questionable part. with compressed air. 1. Clean the caliper body and piston in clean DOT 5 brake fluid or isopropyl alcohol and dry with com- 3. Inspect the piston and cylinder bore wall for pressed air. scratches, scoring or other damage. ------------------------------------------------------------------------------------------------------------------------------------------------------------- BRAKES 479 89 92 Align gap with top of caliper bore Retaining ring 90 Assembly 1. The following parts are included in a H-D rebuild kit (part No. 43946-86): piston seal (A, Figure 89), piston (B), dust boot (C) and retaining ring (D). NOTE Never reuse an old dust boot or piston seal. Minor damage or age deteriora- tion can make the boot and seal useless. 2. Soak the new dust and piston seal in clean DOT5 91 brake fluid. 3. Make sure the retaining ring, piston and caliper bore are thoroughly clean. 4. Install the piston seal (Figure 88) into the caliper 12 body groove. 5. Before installing the piston in the caliper bore, iInstall the piston dust boot on the piston as follows: a. Place the piston on the workbench with its open side facing up. b. Align the piston dust boot with the piston so that the shoulder on the dust boot faces up. c. Slide the dust boot over the piston until the in- 4. Make sure the hole in the bleed valve screw is ner lip on the dust boot seats in the piston clean and open. Clean with compressed air. groove (Figure 90). 6. Coat the piston and caliper bore with DOT 5 5. Check the pin bolts for wear or damage. brake fluid. 6. Replace the pad shims if corroded or damaged. 7. Align the piston with the caliper bore so that its open end faces out (Figure 91), then push the piston 7. Check the brake pads for excessive wear or dam- in until it bottoms out. age. Measure the thickness of the brake pad friction 8. Seat the piston dust boot (B, Figure 83) into the material. Replace the brake pads if they are worn to caliper bore. the service limit dimension listed in Table 1. 9. Find the retaining ring groove in the end of the 8. Check all of the rubber parts for cracks, wear or caliper bore. Then install the retaining ring (Figure deterioration. 85) so that the gap in the ring (Figure 92) is at the | |
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