harley brake caliper removal

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Harley-Davidson CHROME FRONT BRAKE CALIPER KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-11-2010

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See Figure 1. Refer to FRONT BRAKE CALIPERS: REMOVAL in the Service Manual, and follow the instructions to: a. remove the banjo bolt with bleeder valve (2) and both gaskets (4), and b. detach the front brake line (3) from the caliper. c. Discard the gaskets. For this installation, the banjo bolt (2) can also be discarded. d. Remove the caliper mounting bolts (1). Lift the brake caliper assembly upward to remove it from the brake disc. -J03529 1 of 4
2 5 3 4 1 is04104 1. Mounting bolt (2) 2. Banjo bolt with bleeder valve 3. Brake line 4. Gasket (2) 5. Screen cover Figure 1. Remove Existing Caliper 2. Remove the brake pads from the caliper. Refer to BRAKE PADS AND DISCS: BRAKE PAD REPLACEMENT, FRONT BRAKE CALIPER in the Service Manual. a. Remove the screen cover (5) from the caliper. b. See Figure 2. Note the orientation of the brake pads, and remove the retaining clip (2), pad pin (1) and brake pads from the caliper. Also note the position of the brake pads at removal, so they can be installed back in the same location. 3. Repeat the procedure for the opposite-side caliper. 2 1 is04105 1. Pad pin 2. Retaining clip Figure 2. Front Caliper Pad Pin Pad and Pin Inspection 1. Refer to BRAKE PADS AND DISCS: INSPECTION in the Service Manual, and follow the instructions given to inspect the brake pads. If any front brake pad is worn to 0.5 mm (0.020 inch) or less above the backing plate, replace all four front pads. 2. Inspect the brake disc thickness, lateral runout and warpage. If necessary, follow the instructions in the Service Manual under FRONT WHEEL to replace the discs. Chrome Caliper Installation 1. See Figure 3. Obtain the correct-side new chrome caliper assembly from the kit. Remove the screen cover (5), retaining clip and pad pin (4) from the caliper. NOTE Do not remove the shipping plug protecting the brake line threaded hole until ready to install the brake line. 2. Place the caliper over the brake disc with the brake line threaded hole (protected by a shipping plug) facing upward. 3. See Figure 1. Obtain two of the brake caliper mounting bolts (1), removed earlier. Loosely install both bolts through the front fork and into the chrome caliper. Alternately tighten the mounting bolts to 38.0-51.5 Nm (28-38 ft-lbs) . 4. Install the brake pads removed earlier or, if necessary, new brake pads into the caliper. 5. See Figure 2. Install the new pad pin (1) through the inner and outer brake pads. Tighten to 8.5-11.5 Nm (75-100 in- lbs ) . 6. Install the new retaining clip (2) onto the pad pin. NOTE Ensure that the screen cover is oriented with the single tab end up, and the double tab end down. 7. See Figure 1. Install the new screen cover (5) onto the caliper.

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HARLEY DAVIDSON REAR BRAKE CALIPER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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INSTALLATION Prepare the Motorcycle for Service To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Follow the Service Manual instructions to disconnect the negative (-) battery cable. Remove Rear Brake Caliper Remove the Brake Pads 1. For models equipped with saddlebags: Remove the right-side saddlebag. Refer to the SADDLEBAGS section of the Service Manual. 2. Remove the rear master cylinder reservoir cover. 3. Pry both the inside and outside pads away from the brake disc and toward the caliper assembly to push the caliper pistons back into their bores. Use steady pressure to prevent scoring the brake disc. Pry between the pads and the brake disc. 4. When the pistons are fully retracted into their bores, pull the pad pins out to allow the pads to drop from the caliper assembly. Note the pads’ original orientation for installa- tion. 5. Install the cover on the rear master cylinder reservoir. NOTE Place a container under the brake caliper to catch brake fluid released when removing the brake line from the caliper. 6. Remove the banjo bolt fastening the rear brake line to the stock rear brake caliper. Save the banjo bolt for brake caliper installation and discard the two steel/rubber gas- kets. Remove the Stock Rear Brake Caliper 1. Apply isopropyl alcohol to the rubber bumper on the brake caliper to ease removal. 2. Lift the stock rear brake caliper toward the front of the motorcycle. The notch in the caliper must clear the weldment on the swing arm. 3. Remove the caliper from anchor weldment on rear swingarm. Inspect Pad and Pins 1. Inspect the brake pads. If friction material above the backing plate on either pad is 0.040 in. (1.02 mm) thick or less, replace the set. Follow the instructions in the Service Manual. 2. Inspect pad pins for wear and grooving. If wear is more than 0.015 in. (0.38 mm), replace both pins. 3. Inspect the brake disc and, if necessary, follow the instructions in the Service Manual to replace the brake disc. Install the Rear Brake Caliper NOTE Pay close attention to all warnings, cautions, and torque specifications in this instruction sheet and in the service manual when installing this rear brake caliper. NOTE Apply isopropyl alcohol to the rubber bumper for ease of installation. 1. See Figure 1. Position the caliper (1) between the brake disc and the rear fork. The weldment on the fork should fit between the notch and rubber bumper on the caliper. Verify that the full length of the rubber bumper contacts the underside of the weldment

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HARLEY DAVIDSON DUAL DISC FRONT BRAKE KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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This kit is designed for installation on the following models which have original equipment 39mm front fork tubes (including chromed tubes) and 19-in. cast-aluminum front wheels: • 2000 – 2003 XLH 883, XLH 883 Hugger and XLH 1200 • 2000 – 2003 FXD (Super Glide) This kit can also be installed on the above XLH and FXD models which have original equipment 39mm front fork tubes and 19-in. laced front wheels only after one of the following procedures is performed: • The original single-flange hub of the 19-in laced front wheel is replaced with a new double-flange hub (H-D Part No. 43629-00), (sold separately) which will accept the second brake disc. OR • The original 19-in. laced front wheel assembly, which has a single-flange hub, is replaced with a new 19-in. laced front wheel assembly (H-D Part No. 43579-00), (sold separately) which has a double-flange hub designed to accept the second brake disc. See the Service Parts Illustration for a list of the contents included in this kit. This kit does not include the front brake line required for a dual disc system; the brake line must be purchased separately as follows: • For XLH 883 motorcycle equipped with low-rise (flat) handlebars, order dual disc brake line H-D Part No. 45148-96. • For XLH 883 Hugger, XLH 1200, and FXD Super Glide models with “buckhorn” (pull-back) handlebars, order dual disc brake line H-D Part No. 45111-96. The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) Brakes are a critical safety component. Contact a Harley- Davidson dealer for brake repair or replacement. Improperly serviced brakes can adversely affect brake performance, which could result in death or serious injury. (00054a) Removal and Disassembly – Front Brake System NOTE A Service Manual for your motorcycle is available at your Harley-Davidson Dealer. 1. Block motorcycle underneath frame so that front wheel is raised off the ground slightly. 2. Remove original front brake caliper from left side of front fork according to appropriate Service Manual procedures. Let caliper hang loose on brake line. Save all components and fasteners for reinstallation. NOTE Do not operate the front brake lever with the front caliper removed because the piston may be forced from the caliper. Reseating the piston requires disassembly of the caliper . 3. Remove socket head screw which secures a clamp (retains front brake line) to underside of front fork lower bracket (lower triple clamp). Discard clamp and screw. 4. Remove screw, lockwasher, and clamp which secure front brake line to right rear side of front fork upper bracket (upper triple clamp). Save all components for reinstallation. 5. Remove right mirror and, if applicable, right turn signal lamp assembly from original front brake master cylinder casting. Save all components and fasteners for reinstalla- tion.

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HARLEY DAVIDSON SOFTAIL BRAIDED REAR BRAKE LINE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 04-02-2011

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INSTALLATION Direct contact of D.O.T. 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 D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) D.O.T. 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. (00239b) Drain Brake Fluid 1. Pop off bleeder nipple cap on the rear brake caliper. 2. Install one end of a length of plastic tubing over the caliper bleeder valve. Place the free end of the tubing into a suitable container. 3. Open the bleeder valve about 1/2-turn and pump the brake pedal to drain the brake fluid out of the rear brake system. Do not reuse brake fluid. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) Remove Existing Rear Brake Line 1. Disconnect wiring harness connectors from brake light switch spade terminals. Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a) 2. Disconnect existing brake line from rear brake caliper and rear brake master cylinder assembly. Save banjo bolts, but discard brake line gaskets. NOTE This kit contains all gaskets needed for replacement. 3. Carefully make note of rear brake line routing and orientation of banjo fittings, then remove existing brake line. Save hex head screw holding brake light switch manifold to tab on frame, but discard brake line and attaching parts. 4. Unthread brake light switch from brake line. Save switch for later use.

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HARLEY DAVIDSON XL BRAIDED FRONT BRAKE LINE KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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REMOVAL Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 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 D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 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. (00239b) 1. Drain the brake fluid following the instructions in the service manual. Dispose of waste properly. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Disconnect the battery, negative (-) cable first or remove the main fuse. Follow the instructions in the service manual 3. Remove bolt and two sealing washers to disconnect brake line fitting from master cylinder. Discard sealing washers, but save bolt for installation. 4. Remove bolt and two sealing washers to disconnect brake line fitting from front brake caliper. Discard sealing washers, but save bolt for installation. 5. Carefully make note of brake line routing, then remove existing brake line. NOTE This kit contains clamps and cable straps to either replace the original equipment clamps and cable straps being removed or to add additional brake line support. INSTALLATION Install proper length brake lines. Incorrect brake line length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00325a) Replace brake line gaskets. Re-using original gaskets can cause brake failure and loss of vehicle control, which could result in death or serious injury. (00318a) Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a) 1. Position new sealing washers from kit on each side of hydraulic brake fittings (banjo fittings). Small ID washers are for caliper end, large ID washers are for master cylinder end. 2. Insert bolts (removed earlier) through washers and fittings. 3. Hold new braided brake line in position and install bolts into master cylinder and caliper. Tighten only enough to keep banjo fitting in the same orientation as the stock banjo fitting. 4. Verify there is no twist in the brake line. Adjust brake line if necessary. 5. Install clamps from kit by wrapping clamp around braided brake line at each of the clamp mounting locations. Verify clamps are oriented the same as the stock clamps. Install clamp screws but do not tighten. 6. Check entire length of braided brake line: a. Be sure brake line is not twisted. b. Turn handlebars fully-left and right while checking to make sure brake line does not contact any vehicle components. c. Be sure brake line length between clamps is sufficient. 7. Adjust brake line if necessary. 8. Tighten caliper and master cylinder banjo bolts to 20-25 ft-lbs (27-34 Nm) .

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Harley Davidson Sportster 4 Piston Rear Brake Caliper installation Manual

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Filed Under (Harley Davidson) by admin on 02-04-2012

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Installing Rear Caliper – Sportster Models Removing The Stock Brakes SPORTSTER REAR BRAKE SYSTEM 84 & UP MODELS The basic steps are the same to install a PM rear brake caliper kit on any of the late model Harley Davidson “swingarm” style motorcycles; all require the removal of the rear wheel. Using a suitable lift, raise the motorcycle high enough off the ground to allow you to remove the rear wheel assembly. PHOTO 2 W a r n i n g Center the motorcycle on the lift so that it will not fall while you are working on it. Photo 2: Remove the rear brake caliper assembly by unscrewing the 2 caliper mounting bolts that go through the caliper into the caliper mounting bracket. Lift the caliper up and off the mounting bracket and brake rotor, move the caliper back out of your working area. Don’t remove the brake line from the caliper yet; you will do this just before you are ready to hook it up to the new caliper. The brake pads are held into the caliper mounting bracket by 2 spring clips; slide the brake pads out of the mounting bracket and remove the retaining springs. PHOTO 3 Remove Cotter pin and rear axle nut, slide rear axle completely out. Photo 3: Remove nut from Right rear shock and rotate belt guard up. Slide belt off of pulley and roll rear wheel back 6 – 8″. Photo 4: Remove original caliper bracket from swingarm

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HARLEY DAVIDSON VRSC CHROME BRAKE CALIPER INSERT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-02-2011

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This kit fits 2006 and later VRSC model motorcycles.INSTALLATION 1. See Figure 1. Press in the upper tab (3) with a small screwdriver and remove the stock brake caliper insert (1) from the brake caliper (2). NOTE When installing the front caliper insert, position the single prong tab to the top of the caliper. When installing the rear caliper insert, position the single prong tap toward the front of the caliper. 2. Install the the chrome brake caliper insert into the brake caliper with the caliper oriented in the same manner as the stock insert. 1 2 3 is00627 1. Brake caliper insert 2. Brake caliper 3. Single prong tab Figure 1. Front Brake Caliper (VRSCR Model Shown

HARLEY DAVIDSON CHROME 1.00 INCH (25.4 MM) DIAMETER HANDLEBAR KITS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the service manual and follow the instructions given to remove the main fuse. 2. Remove the outer fairing. See the service manual. 3. Remove the fairing cap. See the service manual. 4. FLHX Models: Handlebar-mounted mirrors (purchased separately) are required for proper installation of this handlebar. Removal of the inner fairing may be required, refer to the service manual. If fairing-mounted mirrors are being removed: Install the two small black plugs and large black plugs (purchased separately) to plug the fairing mirror holes. Direct contact of D.O.T. 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 D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will dama ge painted and bod y 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. (00239b) NOTE Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills). Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spillage or splashes of DOT 4 brake fluid. 5. Drain the brake fluid from the front brake reservoir and lines per the instructions in the service manual. NOTE Cover the front fender and the fuel tank with clean shop towels to prevent scratching. 6. Models with Radio: Remove the radio. See the service manual. Models without Radio: Remove the storage box. See the service manual. a. The four socket head screws fastening the radio or storage box to the left and right radio support brackets can be accessed through the oblong holes in the fairing brackets. Use a long shank ball-end socket to remove the screws. b. Pull the radio or storage box forward to remove it from the opening in the inner fairing. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) 7. Remove and retain the button head screw on the underside of the fork stem and bracket assembly that holds the brake line manifold tee. 8. Note the front brake line routing and the orientation of the banjo fittings. Disconnect the brake line from the front brake calipers and the front brake master cylinder assembly. Save the banjo bolts, but discard the two gaskets found at each banjo fitting. See the service manual. 9. Remove the front brake line assembly. NOTES Refer to the parts catalog for this year and model for a replacement OE brake line assembly and clutch cable, if needed. Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory Custom Braided Clutch Cables and Brake Lines that are available. 10. Remove the front brake master cylinder and clutch lever assemblies from the handlebar. 11. Disconnect the clutch cable from the clutch lever. See the service manual.

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HARLEY DAVIDSON DYNA AND SPORTSTER Chrome Front Wheel Spacers INSTALLATION ISNTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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1. Block motorcycle underneath frame so front wheel is raised off the ground. 2. See Figure 1. Remove the upper (1) and lower (2) brake caliper mounting bolts and brake caliper(s) (3). Support caliper(s) using a rubber bungee cord. Be careful not to scratch fender paint. NOTES Do not operate front brake lever with the front wheel removed or the caliper piston may be forced out of piston bores. Reseating the piston requires disassembly of the caliper. Prior to removal, make note of existing left and right spacer location. The new spacers will be installed in the locations. 3. See Figure 3. On left side of wheel, remove axle nut (D), lockwasher (E) and washer (F). Perform the following: 4. Sportster and Dyna (except FXDWG) See Figure 2. Loosen the pinch bolt nut (1) and pull the the axle (2) free. Remove wheel and spacers. Leave bearing(s) in place. Discard spacers. 3 1 2 is04469 1. Brake caliper mounting bolt, long (top) 2. Brake caliper mounting bolt, short (bottom) 3. Brake caliper Figure 1. Caliper Mounting Bolts (Left Side) Dyna and Sportster 3 1 2 is04470 1. Pinch bolt nut 2. Axle 3. Pinch bolt Figure 2. Front Wheel Mounting (Dyna and Sportster Except FXDWG-Right Side) 5. See Figure 3. Obtain the new right (1) and left (2) chrome spacers from kit and install. 6. Apply a light coat of ANTI-SEIZE LUBRICANT (Harley- Davidson Part Number 98960-97) to the axle.
7. Place wheel between sliders and install axle. Verify that axle spacers on right and left side are properly installed. 8. See Figure 3. Install the washer (F), lockwasher (E) and nut (D) onto threaded end of axle (A). 9. In order to properly align the front fork, perform the fol- lowing: a. On the right side of the wheel, insert a 7/16 inch drill bit through the hole in the axle. While holding axle stationary, tighten axle nut to 50-55 ft-lbs (61.0-74.6 Nm) . b. Pull fork leg so that it just contacts drill bit. Tighten according to the following: c. Refer to Figure 2. Tighten the Axle Pinch Bolt Nut to 25-30 ft-lbs (33.9-40.7 Nm) . d. Remove drill bit from axle hole. 10. Follow instructions in Service Manual and install brake caliper to the sliders noting the following: •Loosely install long bolt to the top hole on fork leg. Install the short mounting bolt to the bottom hole and tighten to 28-38 ft-lb (38.0-51.5 Nm) . •Final tighten top bolt to 28-38 ft-lbs (38.0-51.5 Nm) . 11. Repeat Step 10 to install brake caliper on opposite side of wheel. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) 12. Pump brake lever to move pistons out until they contact both brake pads. Verify piston location against pads

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Kymco People 125/ 150 FRONT WHEEL/ FRONT BRAKE/ FRONT SUSPENSION

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Filed Under (Kymco) by admin on 12-12-2010

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SERVICE INFORMATION GENERAL INSTRUCTIONS Remove the motorcycle frame covers before removing the front wheel. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down. During servicing, keep oil or grease off the brake drum and brake linings. Contaminated brake disk or brake pads reduce stopping power. Clean the contaminated brake disk with high-performance brake degreaser and replace the brake pads. Do not use brake fluid for cleaning. Bleed air from the brake system if the brake system is removed or the brake is soft. Do not allow any foreign matters to enter the brake system when filling it with brake fluid. Brake fluid will damage painted surfaces and plastic parts. When servicing the brake system, use shop towels to cover and protect rubber, plastic parts and coated surfaces. Wipe off any spilled brake fluid with a clean shop towel. Inspect the brake system before riding. SPECIFICATIONS Item Standard (mm) Service Limit (mm) Axle shaft runout ─ 0.2 Radial ─ 2.0 Axial ─ 2.0 Front brake lining thickness 5.5 2.75 Front shock absorber spring free length 260 252 Brake disk thickness 3.2_3.5 3.0 Brake disk runout ─ 0.25 Brake master cylinder I.D. 12.700_12.74312.75 Brake master cylinder piston O.D. 12.657_12.68412.64 Brake caliper piston O.D. 33.910_33.93433.901 Brake caliper cylinder I.D.

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