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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