Harley Davidson Dyna evolution 1991-1998. Service manual — page 29

Inspection

1. Inspect the caliper for damage. Do not hone or bore the piston bore.

2. Inspect the hydraulic fluid passageway in the cylinder bore. Make sure it is clean and open. Apply compressed air to the opening and make sure it is clear. Clean out, if necessary, with fresh brake fluid.

3. Inspect the piston and cylinder bore (Figure 31) for scratches, scoring or other damage. Replace worn, corroded or damaged parts.

4. Inspect the banjo bolt and bleed valve threads in the caliper body. If damaged, repair the threads with the proper size thread tap. If the threads are worn or damaged beyond repair, replace the caliper body.

5. Make sure the hole in the bleed valve screw is clean and open. Clean with compressed air.

6. Check the threaded bushing, upper mounting screw and the lower mounting pin for thread damage. Repair threads or replace damaged parts as required. Check the mounting pin shoulder for deep scoring or excessive wear.

7. Check the pad retainer for cracks or damage.

8. Check the brake pads (Figure 8) for wear or damage. Measure the thickness of the brake pad friction material (Figure 9). Replace the brake pads if they are worn to 1/16 in. (1.6 mm) or less. Replace both pad sets (left and right calipers) at the same time.

9. Check all of the rubber parts (dust boot, O-rings, piston seal and hoses.) for cracks, wear or deterioration. Because very minor damage or deterioration can make these parts useless, replace questionable parts. If you plan to reuse a rubber part, clean the part thoroughly in new brake fluid and place on a lint-free cloth until reassembly.

10. Clean all serviceable metal parts with rubbing alcohol.



Assembly

1. The parts equipped in a factory rebuild kit are identified in Figure 32. After replacing all worn or damaged parts, coat the following parts with new DOT 5 brake fluid. To prevent contamination, place the parts on a clean lint-free cloth.

a. Piston.

b. Piston seal.

2. Make sure the retaining ring, piston and caliper bore are thoroughly clean.