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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2009 – Current Harley Davidson Trike Conversion Kit INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 27-02-2012

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1. Place the motorcycle on the lift. 2. Place a suitable Jack under the Frame of the Motorcycle and tie down securely. 3. Remove Drain Plug from Primary Cover Assembly and drain oil. 4. Slide Rubber Boot off of the Clutch Cable Adjuster. Loosen and back the Jam nut away from the Clutch Cable Adjuster. Move Clutch Cable Adjuster towards the Jam Nut to introduce free play in the Clutch Lever. 5. Remove the ¼ – 20 Phillips head screw and Seat. 6. Disconnect and REMOVE battery. 7. Remove two ¼ – 20 flanged hex nuts from the Stud Plate. Remove and save the Passenger Handrail and two ¼ – 20 flanged hex head nuts if equipped. 8. Remove the Saddle Bags. 9. Remove the Right and Left Side Covers. 10. Remove Inner Tour Pak Molded Liner. 11. Disconnect the Tour Pak wiring. 12. Remove four ¼ – 20 HHCS. 13. Remove Tour Pak from Top Support Tube. 14. Remove both saddlebag support rails. 15. Loosen Muffler Clamps on both Mufflers and remove two 5/16 – 18 HHCS per Muffler. Remove and discard both Mufflers. Save Muffler Clamps. 16. Remove right side rear heat shield. 17. Remove and discard Muffler Support Plates. 18. Disconnect the Rear Lamp Wiring Harness and remove from T-stud Clip. 19. Remove four frame cover fasteners and the Left and Right Frame Covers. 20. Remove four Tour Pak Support fasteners and the Tour Pak Support.
7 21. Remove four rear fender fasteners and rear fender. 22. Remove four ½ – 13 HHCS and washers. Remove and discard Rear Air Shocks, Air lines and Air Valve bracket. 23. NOTE: NOTE: NOTE: NOTE: If motorcycle is A.B.S. Equipped refer to A.B.S. Installation Instructions. WARNING: WARNING: WARNING: WARNING: If A.B.S. Equipped DO NOT drain brake fluid. 24. Drain all Brake Fluid from the Rear Brake System. 25. Cut and remove Cable ties and un-clamp Wire Harness Loops from the Rear Brake Line along its length, including Clamps on Swing Arm. 26. Remove and discard Banjo Bolt and Crush Washers on Rear Brake Caliper. 27. Remove the Spring Clip and nut from the Rear Axle. 28. Remove Rear Axle and Rear Wheel Spacers. 29. Push Rear Wheel Assembly forward and slip Rear Belt off of the Rear Sprocket. 30. Remove Rear Brake Caliper. 31. Remove and save the two Retaining Washers from the Stud Plate. Remove and save the Stud Plate. 32. Remove Rear Wheel Assembly. 33. Remove two 3/8 – 16 SHCS. Remove Passenger Footboards.

HARLEY DAVIDSON DYNA GLIDE BRAIDED REAR BRAKE LINE KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-04-2011

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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 rear brake caliper. 2. Install one end of a length of plastic tubing over caliper bleeder valve. Place free end of the tubing in 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. See Figure 1. Disconnect wiring harness connectors from brake light switch spade terminals.

HARLEY DAVIDSON REAR SLOTTED SIX-SPOKE WHEELS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to REAR WHEEL in Service Manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from your dealer. See your dealer for the correct part number for your model motorcycle. NOTE Install long valve stem (43206-01) included in the installation kit. Discard all other valve stems. 2. See Figure 1. Install valve stem assembly (I) on wheel. Refer to TIRES in service manual. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) NOTE For Kits 43928-08 and 43929-08: When installing wheel on 2008 and later XL models, install bearing shim from installation kit under the primary bearing. For Kits 43934-07, 43942-07 and 43972-07: When installing wheel on 2008 and later Dyna models, install bearing shim from installation kit under the primary bearing. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to REAR WHEEL in Service Manual. NOTES The valve stem side of the wheel and machined grooves in the hub face indicate the primary bearing side. Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. 4. Install rear wheel (1), stock axle, and stock spacers to motorcycle. Refer to REAR WHEEL in service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

HARLEY DAVIDSON REAR ROAD WINDER WHEELS INSTALLATION MANUAL

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

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This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 1 and Service Parts Tables. INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to the service manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from you dealer. See your dealer for the correct part number for your model motorcycle. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) 2. See Figure 1. Install valve stem assembly (E) on wheel. Refer to the service manual. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to the service manual. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. The machined grooves in the hub face indicate the primary bearing side. 4. Install rear wheel (1), stock axle and stock spacers to motorcycle. Refer to the service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

HARLEY DAVIDSON REAR DEUCE WHEELS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to REAR WHEEL in Service Manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from your dealer. See your dealer for the correct part number for your model motorcycle. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) 2. See Figure 1. Install valve stem assembly (E) on wheel. Refer to TIRES in Service Manual. 3. Assemble wheel installation kit components, stock brake disc and sprocket to wheel using the appropriate service parts table. Refer to REAR WHEEL in Service Manual. The valve stem side of the wheel is the primary bearing side. NOTES Install the primary bearing first using appropriate Service Manual and WHEEL BEARING REMOVER/INSTALLER. The valve stem side of the wheel is the primary bearing side. 4. Install rear wheel (1), stock axle, and stock spacers to motorcycle. Refer to REAR WHEEL in Service Manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

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HARLEY DAVIDSON SPORTSTER BRAIDED REAR BRAKE LINE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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This kit fits 1988-2003 XL models. INSTALLATION 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) Drain Brake Fluid 1. Remove bleed screw cap on rear brake caliper. 2. Install one end of a length of plastic tubing over caliper bleeder valve. Place free end of the tubing in a suitable container. 3. Open the bleeder valve about one-half turn and pump the brake pedal to drain the brake fluid out of the rear brake system. Do not re-use 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. 2. See Figure 1. Remove screws from the three P-clamps and one bracket used to secure brake line to motorcycle. a. Save all screws except bracket screw and save stock P-clamp, located at the right side sprocket cover, for later use. b. Do not mix up the screws. The screws must go back into the same threaded hole in which they were removed. c. Discard remaining two P-clamps. 3. Note brake line routing, then remove existing brake line. NOTE This kit contains clamps to replace the original equipment clamps removed, except for the small clamp on the right side sprocket cover.

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 REAR TYPHOON WHEELS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-02-2011

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INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to REAR WHEEL in Service Manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from a dealer. See a dealer for the correct part number for your model motorcycle. Use plastic protectors on tire mounting tools and rim clamps when mounting a tire to a painted wheel. For wide low profile tires a tire mounting machine with a second arm to press down on the sidewall while the wheel is rotating is recommended. When mounting tires, liberally use tire lube on the wheel and tire. For tire removal, use plastic inserts between the rim and tire after breaking the bead to create a large enough gap for the rim clamps. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) 2. See Figure 1. Install valve stem assembly (E) on wheel. Refer to TIRES in service manual. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the service parts table. Refer to REAR WHEEL in Service Manual. NOTES Install the primary bearing first using service manual and WHEEL BEARING REMOVER/INSTALLER. The machined grooves in the hub face indicate the primary bearing side. 4. Install rear wheel (1), stock axle, and stock spacers to motorcycle. Refer to REAR WHEEL in service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner

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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