Harley Davidson 2003 VRSCA model. Service manual — page 3

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 could result in death or serious injury.

14. Test brake system.

a. Turn ignition switch ON. Pump brake pedal to verify operation of the brake lamp.

b. Test ride the motorcycle. If the brakes feel spongy, bleed the system. See 1.9 BLEEDING BRAKES.

NOTE

Avoid making hard stops for the first 100 miles (160 km). This allows the new pads to become conditioned to the brake discs.

Front Brake Caliper

1. Remove the front master cylinder reservoir cap. As the pistons are pushed back into the caliper, fluid level may rise more than 1/8 in. (3.2 mm). You may have to remove fluid to allow for this.

2. See Figure 1-33. Loosen, but do not remove, both pad pins (3) (12 pt/0.25 in.).

3. Remove both caliper mounting bolts (1, 2) (metric). Detach caliper from front forks and brake disc.

4. Pry the pads back to force all four caliper pistons into their bores.

5. With the pistons retracted, remove the pad pins and brake pads.

NOTES

• See Figure 1-32. On the right side of the vehicle, the pad with two tabs (1) installs on the inboard side of the caliper.

• On the left side of the vehicle, the pad with two tabs (1), installs on the outboard side of the caliper.

• Do not substitute front and rear brake pads.

6. Install new pads into caliper. Curved portion of pad must

face rear of motorcycle.

7. Loosely install the pad pins until you hear an audible click.

8. Attach caliper to front fork.

a. See Figure 1-33. Place caliper over brake disc with bleeder valve facing upwards.

b. Loosely install long mounting bolt (2) (12 pt/10 mm) into top hole on fork leg.

c. Install short mounting bolt (1) (12 pt/10 mm) into

bottom hole on fork leg. Tighten bottom mounting

bolt to 38.0-51.5 Nm (28-38 ft-lbs).

d. Final tighten the top mounting bolt to 38.0-51.5 Nm (28-38 ft-lbs).

e. Final tighten both pad pins to 20-23 Nm (180-200 in-lbs).

Awarning
Whenever new pads are installed, BEFORE moving motorcycle, you must pump brake fluid until the pistons push the pads against the brake disc. If you don’t pump fluid pressure up again, the brakes will not be available to stop the motorcycle which could result in death or serious injury.

9. Pump brake hand lever to move pistons out until they contact both brake pads. Verify piston location against pads. If the front wheel is off the ground, rotate wheel to check for excessive brake pad drag.

10. Check brake fluid level in master cylinder. Fill to proper level if necessary using D.O.T. 5 SILICONE BRAKE FLUID. Install master cylinder reservoir cap. Tighten reservoir cap screws to 0.7-0.9 Nm (6-8 in-lbs).
Awarning
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 could result in death or serious injury.

11. Test brake system.

a. Turn ignition switch ON. Pump brake hand lever to verify operation of the brake lamp.

b. Test ride the motorcycle. If the brakes feel spongy, bleed the system. See 1.9 BLEEDING BRAKES. *

NOTE

Avoid making hard stops for the first 100 miles (160 km). This allows the new pads to become conditioned to the brake discs.