Harley Davidson 2018 softail models. Service manual — page 6
NOTE
Take care when replacing tire to prevent cosmetic damage to wheel.
1. Deflate tire.
2. Loosen both tire beads from rim flange.
3. Remove tire.
1. Clean.
a. Clean the inside of tire and outer surface of tube.
b. Clean rim bead area with a stiff wire brush.
2. Inspect.
a. Verify that wheel is true. See General.
b. Check tire tread depth.
c. Inspect tire for punctures or tears. Small punctures can be repaired.
WARNING
Replace punctured or damaged tires. In some cases, small punctures in the tread area may be repaired from within the
removed tire by a Harley-Davidson dealer. Speed should NOT exceed 80 km/h (50 mph) for the first 24 hours after
repair, and the repaired tire should NEVER be used over 129 km/h (80 mph). Failure to follow this warning could lead
to tire failure and result in death or serious injury. (00015b)
3. Repair.
a. Patch inner tubes only as an emergency measure. Replace a damaged or patched tube as soon as
possible.
b. Repair tread on tubeless tires if puncture is 6.4 mm (¼ in) or smaller.
c. Make repairs from inside the tire.
d. Always combine a patch and plug when repairing tire.
WARNING
Harley-Davidson recommends the use of its specified tires. Harley-Davidson vehicles are not designed for operation
with non-specified tires, including snow, moped and other special-use tires. Use of non-specified tires can adversely
affect stability, handling or braking and lead to loss of vehicle control, which could result in death or serious injury.
(00024d)
WARNING
Harley-Davidson front and rear tires are not the same. Interchanging front and rear tires can cause tire failure, which
could result in death or serious injury. (00026a)
WARNING
Do not exceed manufacturer's recommended pressure to seat beads. Exceeding recommended bead seat pressure
can cause tire rim assembly to burst, which could result in death or serious injury. (00282a)
For tire pressures, refer to Specified Tires.
NOTE
Mount tires with arrows molded into the tire sidewall pointing in the direction of forward rotation.
If tire has a balance dot on the sidewall, align the balance dot with the valve stem.
Tube-Type Tires
WARNING
Match tires, tubes, rim strips or seals, air valves and caps to the correct wheel. Contact a Harley-Davidson dealer.
Mismatching can lead to tire damage, allow tire slippage on the wheel or cause tire failure, which could result in
death or serious injury. (00023c)
NOTE
For correct tire and tube types, see Chassis.
When replacing a tube-type tire, replace the inner tube and rim strip.
Always use a rim strip on tube-type laced wheels.
1. See Figure 1. Tube-type laced wheels:
a. Verify that no spokes protrude through nipples.
b. Install a new rim strip.
c. Align the valve stem hole in rim strip with valve stem hole in rim.
d. Install new tube and tire.
2. Balance wheel. See Balance.
3. Check tire lateral and radial runout. See Checking Wheel Runout.
4. Install wheel. See Prepare or Prepare.
Figure 1. Installed Rim Strip
Tubeless Tires: Cast Wheels
WARNING
Only install original equipment tire valves and valve caps. A valve, or valve and cap combination, that is too long or
too heavy can strike adjacent components and damage the valve, causing rapid tire deflation. Rapid tire deflation
can cause loss of vehicle control, which could result in death or serious injury. (00281a)
Replace damaged or leaking valve stems.
1. See Figure 2. Metal valve stem.
a. Install rubber grommet (5) on valve stem.
b. Insert valve stem into rim hole.
c. Install metal washer (4) and nut (3). Tighten.
Torque: 1.4-1.7 N·m (12-15 in-lbs) Valve stem nut
2. Rubber valve stem.
a. Cut old valve stem to remove.
b. Install new valve stem.
c. Verify that valve stem is securely seated.
3. Install tire.
4. Balance wheel. See Balance.
5. Check tire lateral and radial runout. See Checking
Wheel Runout.
6. Install wheel. See Prepare or Prepare.
1
Bolt-on valve stem
2
Snap-in valve stem
3
Nut
4
Metal washer
5
Rubber grommet
Figure 2. Tubeless Tire Valve Stems
Lateral Runout
NOTE
Measure runout with wheel installed on motorcycle or using a wheel stand.
Avoid measuring on raised letters or vents.
1. Check tire pressure.
2. See Figure 1. Spin the wheel and measure lateral runout from a fixed point to a smooth area on the tire
sidewall.
3. If lateral runout exceeds 2.29 mm (0.090 in), remove tire from rim and check rim lateral runout. See General.
a. If rim runout is within specification, replace faulty tire.
b. If rim runout is not within specification, adjust spokes on laced wheel or replace cast wheel. See
General.
Figure 1. Checking Tire Lateral Runout
Radial Runout
1. Check tire pressure.
2. See Figure 2. Spin the wheel on the axle and measure radial runout at the tread centerline.
3. If tire runout exceeds 2.29 mm (0.090 in), remove tire from rim and check rim radial runout. See General.
a. If rim runout is within specification, replace faulty tire.
b. If rim runout is not within specification, adjust spokes on laced wheel or replace cast wheel. See
General.
Figure 2. Checking Tire Radial Runout
Static vs Dynamic
Wheel balancing is recommended to improve handling. Balanced wheels reduce vibration especially at high speeds.
Static balancing produces satisfactory results for normal highway speeds. Dynamic balancing can produce better
results for deceleration.
Weights
NOTE
If more than 99.2 g (3.5 oz) of weight is required to balance wheel, rotate the tire 180 degrees on the rim and
again balance the assembly. Balance wheels to within 14 g (0.5 oz).
All wheel weights currently supplied by Harley-Davidson are made from zinc which is lighter than lead. The
weight of each zinc segment is 5 g (0.18 oz) as compared to 7 g (0.25 oz) for lead. Weights are stamped for
easy identification.
If adding more than 43 g (1.5 oz) of weight at one location, divide the amount to apply half to each side of rim.
On cast wheels without a flat area near the bead, place the weights cross-wise through the opening.
1. See Figure 2. Place weights on a smooth surface of the wheel rim such that centrifugal force keeps them in
place. Make sure that the area of application is clean, dry and free of oil and grease.
NOTE
See Figure 1. When installing wheel weights, consider cosmetics. Snaking (1) is not to exceed 1.02 mm
(0.040 in) (2) of straight. The angle alignment of individual segments is not to exceed three degrees (3).
2. Remove paper backing from the weight. Press firmly in place and hold for ten seconds.
1
Snaking
2
Not to exceed 0.040 in (1.02 mm)
3
Not to exceed 3 degrees
Figure 1. Weight Segment Alignment
1
Laced steel
2
Cast (typical with flat bead area)
3
Cast (special with no flat bead area)
Figure 2. Wheel Weight Placement
1. Install wheel. See Prepare or Prepare.
1. Remove mufflers as necessary. See Prepare.
Special Tools
Description
Part Number
Qty.
AXLE ALIGNMENT PLUGS
HD-48856-B
1
WARNING
Only a Harley-Davidson dealer should perform vehicle alignment. Improper alignment can adversely affect stability and
handling, which could result in death or serious injury. (00060a)
WARNING
Check vehicle alignment according to following procedures. Incorrect alignment can adversely affect stability and
handling, which could result in death or serious injury. (00287a)
1. Install rear axle alignment components to rear axle.
Special Tool: AXLE ALIGNMENT PLUGS (HD-48856-B)
a. See Figure 2. Insert alignment plug (2) into left end of
rear axle. Turn handle until plug is firmly held in axle.
b. See Figure 3. Install rear axle alignment tool (4) onto
right end of rear axle over the e-clip.
Measure: Rear Fork Flat
NOTE
This method should be used prior to disassembly if alignment and belt tension are good.
1. See Figure 1. Fabricate an alignment tool.
a. Cut a piece of 3.175 mm (0.13 in) diameter
aluminum welding rod approximately 153 mm (6 in)
long.
b. Bend rod at a 90 degree angle, 76 mm (3 in) (3)
from the flat end.
c. Place a snug-fitting rubber grommet (2) on rod.
2. Measure left side: Measure distance between rear fork
flat and rear axle alignment plug center.
a. See Figure 2. Place end of alignment tool (1)
against rear fork flat (4).
b. Slide rubber grommet (3) along tool shaft until it
aligns with hole in center of rear axle alignment plug
(2).
c. Without moving grommet, position alignment tool on
other side of rear fork.
d. Record measurement.
3. Measure Right side: Measure distance between rear
fork flat and rear axle alignment tool center.
a. See Figure 3. Place end of alignment tool (1)
against rear fork flat (2).
b. If necessary, slide rubber grommet (3) along tool
shaft until it aligns with hole in center of rear axle
alignment tool (4).
c. Record measurement
1
Alignment tool
2
Rubber grommet
3
2.25 in (57 mm)
4
3.75 in (95 mm)
Figure 1. Wheel Alignment Tool
1
Alignment tool
2
Axle alignment plug
3
Rubber grommet
4
Rear fork flat
Figure 2. Rear Axle Alignment: Left Side
1
Alignment tool
2
Rear fork flat
3
Rubber grommet
4
Rear axle alignment tool
Figure 3. Rear Axle Alignment: Right Side
Measure: Rear Fork Pivot Shaft
NOTE
This method should be used if measurement not taken prior to disassembly.
1. See Figure 4. Place a steel rod through rear fork pivot
shaft.
!xsl.publication.measure-prefix-length-diameter!: 8 mm
(5/16 in)
2. Measure the distance between the center of the steel
rod and the axle alignment tools.
a. Using this method, the left and right side
measurements should be equal.
3. Adjust if necessary.
Figure 4. Rear Fork Pivot Shaft Alignment Rod
NOTE
Do not remove E-clip when loosening rear axle nut.
1. Loosen rear axle nut. See Prepare.
2. See Figure 1. Adjust rear axle.
a. Turn axle adjuster screw counterclockwise to shorten distance on the side with the longer distance.
b. If measured from rear fork flats: Adjust axle until left and right side alignment measurements match any
difference from left or right side previously recorded.
c. If measured from rear fork pivot shaft: Adjust axle until measurements on left and right side are equal.
NOTE
Keep axle adjuster mechanisms firmly seated (under tension) on each side of rear fork during wheel alignment.
Do not tighten rear axle nut until after checking drive belt tracking and tension.
3. Verify drive belt deflection. See Inspect.
4. Verify drive belt tracking properly.
WARNING
Do not exceed specified torque when tightening axle nut. Exceeding torque can cause wheel bearings to seize during
vehicle operation, which could result in death or serious injury. (00408e)
5. Tighten rear axle nut. See Prepare.
6. Verify alignment. See Inspect.
Figure 1. Rear Axle Adjustment Screw
1. If removed, install muffler. See Prepare.
1. Remove right mirror. See Remove.
2. Drain brake fluid from front brake system. See Drain.
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage.
(00239c)
NOTICE
Do not allow dirt or debris to enter the master cylinder reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and master cylinder bore are clean and undamaged before
assembly. (00322a)
1. Remove brake line.
a. Remove banjo bolt and two gasket washers.
b. Discard gasket washers.
c. Remove brake line.
2. See Figure 1. Remove screws (17), washers (16),
handlebar clamp (15) and master cylinder.
3. Remove master cylinder.
1
Screws (2)
2
Cover
3
Gasket
4
Pivot pin
5
Bushing
6
Brake hand lever
7
Retaining ring
8
Master cylinder reservoir
9
Primary cup
10
Dust boot
11
Retaining ring
12
Piston
13
Secondary cup
14
Spring
15
Handlebar clamp
16
Washer (2)
17
Screw (2)
Figure 1. Front Brake master Cylinder
1. See Figure 1. Position the brake lever/master cylinder
assembly inboard of the switch housing assembly,
engaging the tab (2) on the lower switch housing (1) in
the groove (3) at the top of the brake lever bracket (4).
2. Secure the handlebar clamp to master cylinder with two
screws (with flat washers). Position hand lever and
controls for rider comfort. Beginning with the top screw,
tighten.
Torque: 6.8-9 N·m (60-80 in-lbs) Handlebar switch
clamp screw
NOTE
See Prepare For proper positioning of hand lever.
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s), brake
line and caliper bore are clean and undamaged
before assembly. (00321a)
3. Attach brake line to master cylinder with banjo bolt and
new gasket washers. Tighten.
Torque: 29-31 N·m (21-23 ft-lbs) Front brake master
cylinder banjo bolt
1
Switch housing assembly
2
Tab
3
Groove
4
Brake lever bracket
Figure 1. Attach Master Cylinder to Right Handlebar Switches
1. See Front Brake master Cylinder. Remove retaining ring
(7) from pivot pin groove at bottom of master cylinder
bracket.
2. Remove pivot pin (4) and brake hand lever (6).
3. Remove dust boot (10) and discard.
4. Remove retaining ring (11).
5. Remove and discard piston assembly (9, 12-14).
6. Remove screws (1), cover (2) and gasket (3).
Consumables
Description
Part Number
Size
DOT 4 BRAKE FLUID
99953-99A
355 ml (12 fl oz)
WARNING
Use denatured alcohol to clean brake system components. Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even after assembly. Deterioration of these components can cause
brake failure, which could result in death or serious injury. (00291a)
WARNING
Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety
glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates.
(00061a)
1. Clean all parts with denatured alcohol or brake fluid.
DOT 4 BRAKE FLUID (99953-99A)
a. Wipe parts dry with a clean, lint-free cloth.
b. Clear drilled passages and bore with clean
compressed air.
2.
NOTE
Do not use a wire or similar instrument to clean drilled
passages in bottom of reservoir.
Inspect parts for wear or damage. Replace parts if
necessary.
3. Inspect the piston bore in the master cylinder housing for
scoring, pitting or corrosion. Replace as necessary.
4. Carefully inspect the outlet port that mates with the brake
line fitting. As a critical sealing surface, replace the
master cylinder assembly if any damage is noted.
5. Carefully inspect the cover gasket for damage. Replace as
necessary.
Consumables
Description
Part Number
Size
CCI #20 BRAKE GREASE
42830-05
29.6 ml (1 fl oz)
1.
NOTE
Always reassemble the master cylinder using
new parts from the correct repair kit.
Use CCI #20 BRAKE GREASE (42830-05) ,
included in kit, to lubricate cylinder bore, cups
and seals before assembly.
See Front Brake master Cylinder. Coat piston bore of
master cylinder reservoir (8), piston (12), primary cup (9)
and secondary cup (13) with grease (supplied in kit). CCI
#20 BRAKE GREASE (42830-05)
2.
Install piston assembly into piston bore of master cylinder
reservoir.
a. Press small end of spring (14) onto piston (12).
b. Install piston/spring assembly into master cylinder
reservoir (8) bore.
3.
Press in on piston (12). Install new retaining ring (11).
4.
Install new dust boot (10). Press large end against
retaining ring. Small end should fit into groove on shaft.
5.
Install gasket (3), cover (2) and screws (1). Leave
fasteners loose.
6.
Coat front brake lever pin pivot hole and on the end of
piston that contacts brake lever with grease (supplied in
kit).
CCI #20 BRAKE GREASE (42830-05)
7.
Assemble brake hand lever (6) with pivot pin (4) to master
cylinder reservoir (8).
WARNING
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip
from the pliers and could be propelled with enough
force to cause serious eye injury. (00312a)
8. Install new retaining ring (7).
1. Fill and bleed front brake system. See Drain.
2. Install right mirror. See Remove.
1. Caliper service only: Drain brake fluid from front brake system. See Drain.
CAUTION
Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with
large amounts of water and get medical attention. Swallowing large amounts of DOT 4 brake fluid can cause digestive
discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN.
(00240b)
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and caliper bore are clean and undamaged before assembly.
(00321a)
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage.
(00239c)
Remove Caliper to Remove Front Wheel
1. See Figure 1. Remove mounting bolts (2). Slide caliper
rearward, and position out-of-way.
Remove Caliper to Remove Front Brake Pads
1. See Figure 1. Loosen brake pad hanger pins (6).
2. Remove mounting bolts (2). Slide caliper rearward, and
position out-of-way.
Remove Caliper for Service
1. See Figure 1. Loosen brake pad hanger pins (6).
2. Remove banjo bolt (4).
a. Remove banjo bolt.
b. Remove and discard gasket washers (5).
3. Loosen bridge bolts (7).
4. Remove mounting bolts (2). Slide caliper rearward, and
remove front brake caliper.
1
WSS (Wheel speed sensor) harness retainer - ABS
(Anti-lock braking system) only
2
Caliper mounting bolt (2)
3
Front brake line
4
Banjo bolt
5
Gasket washer (2)
6
Brake pad hanger pin (2)
7
Bridge bolt (4)
Figure 1. Front Brake Caliper: (Typical)
Consumables
Description
Part Number
Size
DOT 4 BRAKE FLUID
99953-99A
355 ml (12 fl oz)
Install Caliper After Service
1.
NOTE
ABS Models: Install WSS (Wheel speed sensor)
harness retainer (1) when installing caliper to front
fork.
See Front Brake Caliper: (Typical). Install caliper.
a. Slide caliper forward, guiding the brake pads
around brake rotor.
b. Align the caliper with the mounting bolt holes.
2.
Install mounting bolts (2). Tighten.
Torque: 38-51.5 N·m (28-38 ft-lbs) Front brake caliper
mounting bolts
3.
Install banjo bolt (4).
a. Lubricate new gasket washers (3) with brake fluid.
DOT 4 BRAKE FLUID (99953-99A)
b.
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s),
brake line and master cylinder bore are clean
and undamaged before assembly. (00322a)
Install banjo bolt, new gasket washers (1) and front
brake line (3). Tighten.
Torque: 19-24.4 N·m (14-18 ft-lbs) Front brake
caliper banjo bolt
4.
Tighten bridge bolts (7).
Torque: 19.6-24.5 N·m (14-18 ft-lbs) Front brake
caliper bridge bolt
5.
Tighten brake pad hanger pin (6).
Torque: 14.7-19.6 N·m (11-14 ft-lbs) Front brake
caliper pad hanger pin
Install Caliper After Installing Front Brake Pads
1.
NOTE
ABS Models: Install WSS harness retainer (1)
when installing caliper to front fork.
See Front Brake Caliper: (Typical). Install caliper.
a. Slide caliper forward, guiding the brake pads
around brake rotor.
b. Align the caliper with the mounting bolt holes.
2. Install mounting bolts (2). Tighten.
Torque: 38-51.5 N·m (28-38 ft-lbs) Front brake caliper
mounting bolts
3. Tighten brake pad hanger pin (6).
Torque: 14.7-19.6 N·m (11-14 ft-lbs) Front brake
caliper pad hanger pin
Install Caliper After Installing Front Wheel
1.
NOTE
ABS Models: Install WSS harness retainer (1)
when installing caliper to front fork.
See Front Brake Caliper: (Typical). Install caliper.
a. Slide caliper forward, guiding the brake pads
around brake rotor.
b. Align the caliper with the mounting bolt holes.
2. Install mounting bolts (2). Tighten.
Torque: 38-51.5 N·m (28-38 ft-lbs) Front brake caliper
mounting bolts
3. ABS models: Verify WSS wire harness clips are in
place.
NOTE
Avoid making hard stops for the first 160 km (100 mi). This allows the new pads to become conditioned to the
brake discs.
1. Remove one brake pad. See Inspect.
2. Verify that remaining brake pad is installed with brake pad
pins.
3. Verify that bleeder screw is installed.
NOTE
Do not damage banjo bolt sealing surface or threads
of banjo bolt hole in brake caliper. Use an air nozzle
with a rubber tip.
WARNING
Compressed air can pierce the skin and flying debris
from compressed air could cause serious eye
injury. Wear safety glasses when working with
compressed air. Never use your hand to check for
air leaks or to determine air flow rates. (00061a)
CAUTION
When removing piston with compressed air, piston
can develop considerable force and fly out of
caliper bore. Keep hands away from piston to avoid
possible injury. (00530b)
4. Gently apply low pressure compressed air to banjo bolt
hole to force pistons from caliper bores.
5. Remove brake pad pins and brake pad.
6. See Figure 1. Remove bridge bolts (11, 12) and separate
caliper housings.
7. Remove pistons from each housing by hand. If necessary,
wiggle pistons gently to remove.
NOTE
Damaged piston bores leak when reassembled. Do
not use metal objects to remove or install objects
from piston bores. Prevent damage to pistons, seals
and bores by only using a wooden toothpick when
servicing calipers.
8. Using a wooden toothpick, remove dust seals (5, 9) and
piston seals (4, 10) from each caliper bore. Discard seals.
9. If necessary, remove bleeder screw (1).
1
Bleeder screw
2
Bleeder screw cap
3
Outer caliper housing
4
34 mm seal (2)
5
34 mm dust seal (2)
6
34 mm piston (2)
7
Cross-over seal
8
32 mm piston (2)
9
32 mm dust seal (2)
10
32 mm seal (2)
11
Short bridge bolt (2)
12
Long bridge bolt (2)
Figure 1. Front Caliper
Consumables
Description
Part Number
Size
DOT 4 BRAKE FLUID
99953-99A
355 ml (12 fl oz)
WARNING
Use denatured alcohol to clean brake system components. Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even after assembly. Deterioration of these components can cause
brake failure, which could result in death or serious injury. (00291a)
1.
Clean all rubber parts with brake fluid. Do not contaminate
with mineral oil or other solvents. Clean all metal parts
with denatured alcohol. Wipe parts dry with a clean, lint-
free cloth.
DOT 4 BRAKE FLUID (99953-99A)
WARNING
Compressed air can pierce the skin and flying debris
from compressed air could cause serious eye
injury. Wear safety glasses when working with
compressed air. Never use your hand to check for
air leaks or to determine air flow rates. (00061a)
2.
Blow out drilled passages and piston bore with low
pressure compressed air from a clean air supply. Do not
use a wire or similar instrument to clean drilled passages.
3.
Carefully inspect all components. Replace as necessary.
a. Check pistons for pitting, scratches or corrosion on
outside surfaces.
b. Inspect piston bores. Do not hone bores. Replace as
necessary.
NOTE
The pad pins are manufactured with a relief near
the center of their length, where the pad spring
touches. Do not use this area as a measurement
point to determine pad pin wear.
c. Inspect pad pin for grooving and wear at the pad
contact points. Measure the pad pin diameter in an
unworn area and in an area of any grooving or wear.
If wear exceeds 0.28 mm (0.011 in), replace pad pin.
d. Inspect pad spring for wear or cracks. Replace if
necessary.
e. Always replace all seals after disassembly.
WARNING
Always replace brake pads in complete sets for
correct and safe brake operation. Improper brake
operation could result in death or serious injury.
(00111a)
4. Inspect brake pads and brake disc. Replace if necessary.
a. Specifications: content: See Inspect.
b. Brake Disc: See Prepare.
Consumables
Description
Part Number
Size
G40M BRAKE GREASE
42820-04
29.6 ml (1 fl oz)
LOCTITE 569 BROWN THREAD
Loctite 569
50 ml
SEALANT
1.
Lubricate the following parts using a light coat of grease.
All other surfaces must be dry.
G40M BRAKE GREASE (42820-04)
a. Nose radius of pistons.
NOTE
Damaged piston bores leak when
reassembled. Do not use metal objects to
remove or install objects in piston bores.
Prevent damage to bores by only using a
wooden toothpick when servicing calipers.
Pistons and bores differ slightly in diameter:
one large and one small in each housing.
b. All surfaces of piston seals and dust seals.
2.
See Front Caliper. Install a new piston seal (4, 10) and a
new dust seal (5, 9) into each piston bore.
3.
Carefully insert pistons (6, 8) by hand, nose radius first,
into caliper bores. If installation shows resistance, remove
pistons. Check that seals are properly installed and fully
seated in grooves. Press pistons completely into bores.
4.
Install new cross-over seal (7).
5.
Install bridge bolts (11, 12).
a. Apply a drop of threadlocker to the threads of the
bridge bolts.
LOCTITE 569 BROWN THREAD SEALANT (Loctite
569)
b. Assemble caliper housings.
c. Install bridge bolts. Tighten.
Torque: 19.6-24.5 N·m (14-18 ft-lbs) Brake caliper,
front, bridge bolt
6.
Install bleeder screw on caliper housing if removed.
Tighten.
Torque: 3.9-6.9 N·m (35-61 in-lbs) Front brake caliper
bleeder screw
1. If drained: Fill and bleed front brake system. See Drain.
1. Drain brake fluid from rear brake system. See Drain.
2. If needed: Remove right footboard/footpeg bracket. See
Remove and Install: Forward Foot Controls.
1. See Figure 1. Remove cotter circle (1).
2. Remove clevis pin.
1
Cotter circle
2
Clevis pin
Figure 1. Rear Master Cylinder - Rear View: (exhaust remove for clarity)
3. See Figure 2. Remove banjo bolt (2) and two gasket
washers (1) to disconnect fitting of hydraulic brake line
from master cylinder. Discard washers.
4. Remove screws (4).
1
Gasket washer (2)
2
Banjo bolt
3
Brake line
4
Screw (2)
Figure 2. Rear Master Cylinder - Front View: (exhaust remove for clarity)
5. Remove rear master cylinder bracket.
a. See Figure 3. Remove screw (3).
b. Remove rear master cylinder bracket.
1
Partial lower frame rail
2
Rear master cylinder bracket - Mid controls
3
Screw
4
Rear master cylinder bracket - Forward controls
Figure 3. Rear Master Cylinder Bracket
1.
NOTE
Verify that the brake pedal link is between the master
cylinder yoke when placing the master cylinder into
place.
Install rear master cylinder onto rear master cylinder
bracket. Hand tighten.
2.
See Rear Master Cylinder - Rear View: (exhaust
remove for clarity). Install clevis pin.
3.
Install cotter circle.
4.
Position rear master assembly into place on frame.
5.
See Rear Master Cylinder Bracket. Install screw.
Tighten.
Torque: 40.7-54.2 N·m (30-40 ft-lbs) Master cylinder
bracket to frame screw
6.
See Rear Master Cylinder - Front View: (exhaust
remove for clarity). Install screws (4). Tighten.
Torque: 24.4-29.9 N·m (18-22 ft-lbs) Brake master
cylinder, rear, mounting screws
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s), brake
line and caliper bore are clean and undamaged
before assembly. (00321a)
7.
Attach brake line (3) to master cylinder with banjo bolt (2)
and new gasket washers (1). Tighten.
Torque: 19-24.4 N·m (14-18 ft-lbs) Master cylinder, rear,
banjo bolt
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