Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual

Table 3 FRONT SUSPENSION TORQUE SPECIFICATIONS (continued)

ft.-lb.

in.-lb.

N•m

Fork stem pinch bolt

(1988-2003 models)

–

Fork upper bracket pinch bolt

1986-1987 models

21-27

–

29-37

1988-2003 models

–

Handlebar clamp bolts

–

144-180

16-20

*Other models no specification available.

FRONT SUSPENSION AND STEERING

525

CHAPTER FIFTEEN

REAR SUSPENSION

This chapter covers the rear suspension. Refer to Chapter

Thirteen for rear wheel, hub, rear axle and tire service in-
formation.

Tables 1 are located at the end of this chapter.

WARNING

Replace all rear suspension fasteners with
parts of the same type. Do not use a replace-
ment part of lesser quality or substitute de-
sign, as this may affect the performance of the
system or result in failure of the part, leading
to loss of motorcycle control. Use the torque
specifications listed during installation to en-
sure proper component retention.

SHOCK ABSORBERS

The rear shocks are spring controlled and hydraulically

damped. Spring preload can be adjusted on all models.

Spring Preload Adjustment

NOTE

On 1200S models, both the front and rear sus-
pension spring preload is adjustable. Refer to

Front Fork (1200S Models)

in Chapter

Fourteen for the spring preload adjustment
procedure.

On all models, the shock absorber springs can be ad-

justed to suit rider and load. Rotate the cam ring (Figure 1)
at the base of the spring to compress the spring for heavier
loads or extend the spring for lighter loads. Use a spanner
wrench to rotate the cam ring.

Damping Adjustment

The 1200S model rear shock absorbers are adjustable for

compression and rebound damping.

WARNING

Compression and rebound damping settings
must be equal on both sides of the motorcycle.
Handling will be adversely affected if damp-
ing is not the same on both shocks.

1. Adjust the suspension preload as described in

Front

Fork (1200S Models)

in Chapter Fourteen.

2. The shock absorbers on the 1200S models have 14 com-
pression damping settings. Setting 1 (fully clockwise) is the
hardest; setting 14 (fully counterclockwise) the softest. The

recommended setting is eight clicks from the hardest
setting.

NOTE

To ensure the desired results, do not adjust the
damping more than two clicks without testing
the setting.

a. Turn the compression damping adjuster (A, Figure

2) one or two clicks. Turning the adjuster clockwise
increases compression damping, counterclockwise
decreases compression damping.

b. Set the compression damping adjuster on the other

shock absorber to the same setting.

c. Test ride the motorcycle.
d. Repeat the above steps until compression damping is

at the desired level.

3. The 1200S model shock absorbers have 15 rebound
damping settings. Setting 1 (fully clockwise) is the hardest;
setting 15 (fully counterclockwise) the softest. The recom-
mended setting is six clicks from the hardest setting.

a. Turn the rebound damping adjuster (B, Figure 2) one

or two clicks. Turning the rebound adjuster clock-
wise increases rebound damping; counterclockwise
decreases rebound damping.

b. Set the rebound damping adjuster on the other shock

absorber to the same setting.

c. Test ride the motorcycle.
d. Repeat the above steps until you obtain the desired

rebound damping.

Removal/Installation

Removal and installation of the rear shocks is easier if

they are serviced separately. The remaining unit will sup-
port the rear of the motorcycle and maintain the correct re-
lationship between the top and bottom mounts. If both
shock absorbers must be removed at the same time, cut a
piece of steel a few inches longer than the shock absorber
and drill two holes in the steel the same distance apart as the
bolt holes in a shock absorber. Install the steel support after
one shock absorber is removed. This will allow the motor-
cycle to be easily moved around until the shock absorbers
are reinstalled or replaced.
1. Support the motorcycle so that the rear wheel clears the
ground.

NOTE

In Step 2A or 2B, 1200S models are not
equipped with washers or a stud cover (

Fig-

ure 3

). Remove the appropriate fastener.

2A. On 1986-1999 models, remove the upper Acorn nut,
washer, stud cover and washer (Figure 4).
2B. On 2000-2003 models except 1200S models, remove
the upper bolt, washer, stud On cover and washer (Figure 5).
3. Remove the lower locknut, bolt and washer.
4. Remove the shock absorber (Figure 6).

REAR SUSPENSION

527

SHOCK ABSORBER

(1200S MODELS)

1. Shock absorber
2. Bushing
3. Upper spring cover
4. Lower spring cover

5. Install by reversing the preceding removal steps while
noting the following:

a. Apply threadlock (Loctite 242 or equivalent) to the

upper and lower shock fasteners threads.

b. Tighten the upper and lower fasteners as noted in Ta-

ble 1.

Disassembly/Reassembly

Refer to Figure 3, Figure 4 and Figure 5. The shock ab-

sorber body and spring are not available separately.
1. Remove the shock absorber as described in this section.
2. Adjust the cam ring to its softest setting.

WARNING

Do not attempt to remove the shock absorber
spring without a spring compression (part
No. HD-97010-52A or equivalent) or bodily
injury may result.

3. Using a shock absorber spring compression tool, com-
press the shock absorber spring and remove the upper
spring retainer. Figure 7 shows a typical spring compres-
sor.
4. Release spring pressure, then remove the shock ab-
sorber assembly from the tool.
5. Disassemble the shock absorber.
6. Inspect the shock absorber as described in this section.
7. Assembly is the reverse of the removal steps. Lightly
grease all cam parts before assembly.

Inspection

Inspect all parts for wear or damage.

1. Replace all rubber bushings that show signs of wear,
damage or cracking.
2. Check the shock absorber for fluid leaks. Replace the
shock body if leaking.

SWING ARM

Removal/Installation

Refer to Figure 8.

1. Remove the rear wheel as described in Chapter
Thirteen.

CAUTION

Cover the frame, swing arm, rear wheel and
adjacent parts to protect them from acciden-
tal brake fluid spills. Brake fluid can damage
painted and plastic surfaces. Immediately
wash the surfaces that come into contact with
brake fluid with soapy water and rinse com-
pletely.

2. Disconnect all brake hose clamps from the swing arm.

3. Remove the rear brake caliper as described in Chapter
Sixteen. It is not necessary to disconnect the brakelines.
Make sure to support the brake caliper so it is not hanging
from the brake line.
4. Remove the bolts or nuts securing the shock absorbers
to the swing arm and pull the shock absorbers clear of the
mounts.
5. Remove the fasteners securing the rear chain guard and
remove the guard.
6. Remove the pivot shaft covers (Figure 9), if so
equipped.
7. Prior to completing swing arm removal, check its condi-
tion by grasping the swing arm on both sides and trying to
move it from side to side. If the free play is excessive, re-
place the swing arm bearings as described in

Swing Arm

Bearing Replacement

in this section. The manufacturer

does not list free play specifications.
8. Remove the socket screw from the left side (Figure 10).
9. Remove the swing arm pivot bolt (Figure 11).

528

CHAPTER FIFTEEN

SHOCK ABSORBER

(ALL 1986-1999 MODELS

EXCEPT 1200S)

1. Bolt
2. Locknut
3. Bushing
4. Rear shock absorber
5. Washer
6. Stud cover
7. Acorn nut
8. Locknut

9. Washer

10. Bolt
11. Spring retainer
12. Cover
13. Spring
14. Spring guide
15. Cam ring

CAUTION

Keep all bearing components together. If they
fall out, reinstall them into their correct as-
sembled positions. Wear patterns have devel-
oped on these parts and rapid wear may
occur if the components are intermixed and
not installed in their original positions.

10. Slide the swing arm out of the frame. Make sure the
bearings do not drop to the ground.
11. Remove the pivot spacer (11, Figure 8) from the swing
arm.
12. Remove the dust shields (2, Figure 8), inner bearing
race (3, Figure 8), outer bearing race (4, Figure 8) and

REAR SUSPENSION

529

REAR SHOCK ABSORBER

(ALL 2000-2003 MODELS EXCEPT 1200S MODELS)

1. Bolt
2. Washer
3. Stud cover
4. Washer
5. Bushing
6. Shock absorber
7. Bolt
8. Washer
9. Nut

10. Cam ring
11. Spring guide
12. Spring retainer
13. Cover

bearing spacer (6, Figure 8). Make sure to keep all the bear-
ing components together and with their correct assembled
positioned
13. Install by reversing the preceding removal steps while
noting the following.

a. Coat the swing arm pivot shaft thoroughly with bear-

ing grease before installation.

b. Lubricate the bearings with waterproof bearing

grease.

CAUTION

The bearing spacer must be installed between
the bearings as described or the bearings will
fail during operation.

c. Install the bearing spacer between the right side bear-

ings.

d. Install new dust shields with their lip side positioned

in toward the inner bearing races.

WARNING

Install the pivot spacer (11,

Figure 8

) so the

chamfered end faces out (left side). If the
pivot spacer is installed incorrectly unstable
handling may result from an insufficient
clamp load.

e. Install the pivot spacer (11, Figure 8) into the pivot

bushing (8, Figure 8) in the swing arm.

f. If the engine is installed in the frame, insert the screw

(9, Figure 8) into the pivot spacer (11, Figure 8).

g. Slide the swing arm into position in the frame.
h. Install the pivot bolt (Figure 11) from the right side.

Apply threadlock (Loctite 242 or equivalent) to the
threads of the screw and thread the screw (Figure 10)
onto the end of the pivot shaft. Tighten the pivot shaft
bolt to 50 ft.-lb. (68 N

•

m).

i. Tighten the lower shock absorber fasteners to specifi-

cations in Table 1.

j. Install the rear brake caliper (Chapter Sixteen).
k. Adjust the drive chain or drive belt and rear brake

(Chapter Three).

Swing Arm Bearing Replacement

Refer to Figure 8.

1. Secure the swing arm in a vise with soft jaws.

CAUTION

Tag each component when removed from the
swing arm so it can be reinstalled in its origi-
nal position. Bearing components must not be
intermixed. Wear patterns develop on bear-
ing assemblies and rapid wear may occur if
the components are not installed in their orig-
inal positions.

2. Remove the following parts from the right side in the
following order:

a. Dust shields (2, Figure 8).

b. Bearings (3, Figure 8).

CAUTION

Unless replacement is required, do not re-
move the outer bearing races or the pivot
bushing. The complete bearing assembly
must be replaced as a unit if any one bearing
part is worn or damaged.

NOTE

Steps 3-9 require the use of a hydraulic press.
Refer service to a dealership if a press is not
available. Do not attempt to drive the bearing
races or pivot bushing out of the swing arm.

3. Press the outer bearing races (4, Figure 8) out of the
swing arm.

4. Remove and discard the lock ring (5, Figure 8).

5. Remove the bearing spacer (6, Figure 8).

6. Press the right pivot bushing (8, Figure 8) out of the
swing arm.

7. Clean the inside of the swing arm with solvent and dry
with compressed air.

8. Install a new lock ring (5, Figure 8).

530

CHAPTER FIFTEEN

CAUTION

Never reinstall an outer bearing race that has
been removed. During removal it may twist,
which will affect swing arm alignment.

9. Press new bearing races (4, Figure 8) into position.
10. Press a new pivot bushing (8, Figure 8) into the swing
arm on the left side.
11. Apply bearing grease to all parts.

WARNING

Install the pivot spacer (11,

Figure 8

) so the

chamfered end faces outward (left side). If the
pivot spacer is installed incorrectly, unstable
handling may result from an insufficient
clamp load.

12. Install the pivot spacer (11, Figure 8) into the pivot
bushing.

WARNING

The bearing spacer must be installed be-
tween the bearing races during bearing in-

stallation or the bearings will fail during
operation.

13. Install the bearings and bearing spacer (6, Figure 8) in
the order shown in Figure 8.
14. Install dust shields over the bearing. The dust shield lip
must face in.

532

CHAPTER FIFTEEN

Table 1 REAR SUSPENSION TORQUE SPECIFICATIONS

ft.-lb.

in.-lb.

N•m

Swing arm pivot shaft bolt*

–

Rear shock absorber fasteners*

Upper

1986-1992 models

21-27

–

28-37

1993-2003 models

21-35

–

28-47

Lower

1986-1992 models

50-55

–

68-75

1993-2003 models

30-50

–

41-68

*Apply threadlock (Loctite 242 or equivalent).

CHAPTER SIXTEEN

BRAKES

This chapter covers the front and rear brakes. Table 1 and

Table 2 are at the end of this chapter.

BRAKE FLUID SELECTION

WARNING

Do not use brake fluid labeled DOT 5.1. This
is a gylcol-based fluid that is not compatible
with silicone-based DOT 5. DOT 5 brake
fluid is purple while DOT 5.1 is amber/clear.
Do not intermix these two different types of
brake fluid as it can cause brake component
damage and lead to brake system failure.

WARNING

Do not intermix DOT 3, DOT 4 or DOT 5.1
brake fluids as they are not silicone-based.
Using non-silicone brake fluid in these mod-
els can cause brake failure.

CAUTION

Never reuse brake fluid (like fluid expelled

during brake bleeding). Contaminated brake
fluid can cause brake failure. Dispose of used

brake fluid according to local or EPA toxic
waste regulations.

When adding or replacing brake fluid, only use

silcone-based DOT 5 brake fluid.

BRAKE SERVICE

WARNING

Do not ride the motorcycle unless the brakes
work correctly. The proper operation of this
system depends on a supply of clean brake
fluid (DOT 5) and a clean work environment
when any service is being performed. Any tiny
particle of debris that enters the system can
damage the components and cause poor
brake performance.

WARNING

When working on the brake system, do not in-
hale brake dust. It may contain asbestos,
which is a known carcinogen. Do not use
compressed air to blow off brake dust. Use an
aerosol brake cleaner. Wet down the brake
components before working on the brake sys-

tem. Dispose of all brake dust and cleaning
materials properly. Wear a facemask that
meets OSHA requirements. Wash thoroughly
after completing the work.

The disc brake system transmits hydraulic pressure from

the master cylinders to the brake calipers. This pressure is
transmitted from the calipers to the brake pads, which grip
both sides of the brake discs and slow the motorcycle. As
the pads wear, the pistons move out of the caliper bores to
automatically compensate for wear. As this occurs, the fluid
level in the master cylinder reservoir goes down. This must
be compensated for by occasionally adding fluid.

Use only fluid clearly marked DOT 5. If possible, use the

same brand of fluid. Do not replace the fluid with a gly-
col-based fluid (DOT 3, 4 or 5.1). It is not possible to remove
all of the old fluid. Other types are not compatible with DOT

5. Do not reuse drained fluid. Discard old fluid properly. Do
not combine brake fluid with fluids for recycling.

Perform brake service procedures carefully. Do not use

any sharp tools inside the master cylinders or calipers or on
the pistons. Damage of these components could cause a loss
of system hydraulic pressure.

Consider the following when servicing the brake system:

1. The hydraulic components rarely require disassembly.
Make sure it is necessary.

2. Keep the reservoir covers in place to prevent the entry of
moisture and debris.

3. Clean parts with an aerosol brake parts cleaner or dena-
tured alcohol. Never use petroleum-based solvents on inter-
nal brake system components. They will cause seals to
swell and distort.

534

CHAPTER SIXTEEN

FRONT BRAKE CALIPER

(1986-1999 MODELS)

1. Screw
2. Pad retainer
3. Inner brake pad
4. Outer brake pad
5. Retaining ring
6. Dust boot
7. Piston
8. Piston seal
9. O-rings

10. Spring clip

11. Caliper body
12. Bleed valve
13. Washer
14. Upper mounting screw
15. Lower mounting pin

16A. Threaded bushing (1986-1991 models)
16B. Threaded bushing (1992-1999 models)

17. Pin boot

18A. Pad holder (1986-1991 models)
18B. Pad holder (1992-1999 models)

4. Do not allow brake fluid to contact plastic, painted or
plated parts. It will damage the surface.

5. Before performing any procedure where there is a possi-
bility of brake fluid contacting the motorcycle, cover the
work area with a heavy tarp or a large piece of plastic.

6. Before handling brake fluid or working on the brake
system, fill a small container with soap and water and keep
it close to the motorcycle while working. If brake fluid
contacts the motorcycle, clean the area and rinse thor-
oughly.

7. To help control the flow of brake fluid when filling the
reservoirs, punch a small hole into the seal of a new con-
tainer next to the edge of the pour spout.

8. If the hydraulic system, not including the reservoir
cover, has been opened, bleed the system to remove air
from the system. Refer to

Bleeding the System

in this chap-

ter.
9. Dispose of brake fluid properly.

FRONT BRAKE PADS

(1986-1999 MODELS)

There is no recommended mileage interval for chang-

ing the front brake pads. Pad wear depends on riding hab-
its and conditions. Frequently inspect brake pads for
wear. Increase the inspection interval when the wear in-
dicator reaches the edge of the brake disc. After removal,
measure the thickness of each pad. Replace the pads if
they are worn to 0.062 in. (1.6 mm).

Always replace the front brake pads as a set. If equipped

with dual front calipers, never replace the brake pads in one
caliper without also replacing them in the other caliper.

Do not disconnect the brake hose from the caliper for

brake pad replacement. Only disconnect the brake hose if
the caliper is going to be removed.

As the brake pads wear, the brake fluid level drops in the

reservoir and automatically adjusts for wear. Check brake
fluid level often.

Inspection

Refer to

Periodic Maintenance

in Chapter Three.

Replacement

Refer to Figure 1.

1. Review

Brake Service

in this chapter.

2. Place a spacer between the brake lever and the throttle
grip, and secure it in place. If the brake lever is inadver-
tently applied, this prevents the pistons from being forced
out of the cylinders. If the piston is pushed out of the cylin-
der the caliper must be reassembled as described in

Front

Brake Caliper (1986-1999 Models)

in this chapter.

3. Loosen the upper mounting screw (A, Figure 2) and the
lower mounting pin (B). Remove the upper screw and its
washer and the mounting pin.
4. Lift the brake caliper off of the brake disc.

NOTE

If the brake pads will be reused, mark each
pad so that it can be reinstalled in its original
mounting position in the caliper.

5. Remove the outer pad, pad holder and spring clip as an
assembly (Figure 3).
6. Remove the screw (A, Figure 4), pad retainer (B) and
inner pad (Figure 5).
7. Push the outer pad (A, Figure 6) free of the spring clip
(B) and remove it. See Figure 7.

BRAKES

535

8. Check the brake pads (Figure 7) for wear or damage.
Replace the brake pads if they are worn to 0.062 in. (1.6
mm) or less (Figure 8). Replace both pads as a set.
9. Inspect the caliper upper mounting screw (A, Figure 9)
and mounting pin (B). If either part has damaged threads or
is worn or badly corroded, replace the damaged part. Re-
place the mounting pin if its shoulder is scored or otherwise
damaged.
10. Replace the pad retainer (Figure 10) if cracked or de-
formed.
11. Check the piston dust boot (Figure 11). If the boot is
swollen or cracked or if brake fluid is leaking from the cali-
per bore, remove the caliper and overhaul it as described in

Front Brake Caliper

in this chapter.

12. Remove all corrosion from the pad holder.
13. Replace the spring clip (B, Figure 6) if worn, cracked
or badly corroded.
14. Check the brake disc for wear as described in this chap-
ter. Service the brake disc if necessary.
15. Assemble the pad holder, spring clip and outer brake
pad (Figure 12) as follows:

a. Lay the pad holder on a workbench so the upper

mounting screw hole is positioned at the upper right
as shown in A, Figure 13.

b. Install the spring clip (B, Figure 13) at the top of the

pad holder so the spring loop faces in the direction
shown in Figure 12.

c. The outer brake pad (A, Figure 6) has an insulator

pad mounted on its backside.

d. Center the outer brake pad into the pad holder so the

lower end of the pad rests inside the pad holder. Then
push firmly on the upper end of the brake pad, past
the spring clip and into the holder. The pad should be
held firmly by the spring in the spring holder. Refer to
Figure 13.

CAUTION

Do not allow the master cylinder to overflow.
Brake fluid back flows to the reservoir as the
pistons are pushed back into their bores. Be-
cause brake fluid damages most surfaces, im-
mediately wash spilled brake fluid off

536

CHAPTER SIXTEEN

surfaces it contacts. Use soapy water and
rinse completely.

16. Remove the master cylinder cover (Figure 14) and dia-
phragm. Use a shop syringe and remove about 50% of the
brake fluid in the reservoir. This prevents the master cylin-
der from overflowing when the pistons are compressed for
pad installation. Do not drain more than 50% of the brake
fluid, or air may enter the system. Discard fluid properly.

17. Push the piston into the cylinder with your fingers. Re-
install the master cylinder cover and diaphragm, but do not
tighten the screws.

NOTE

The piston should move freely. If not, and
there is evidence of it sticking in the caliper
bore, remove the caliper and service it as de-
scribed in this chapter.

18. Install the inner brake pad (Figure 5) in the caliper re-
cessed seat. The inner pad does not have an insulator back-
ing.

19. Insert the pad retainer (B, Figure 4) in the caliper
counterbore. Install the self-tapping screw (A, Figure 4)
through the pad retainer and thread it into the brake pad.
Tighten the screw to 40-50 in.-lb. (5-6 N•m).

20. Insert the outer brake pad/pad holder assembly into the
caliper so that the brake pad insulator backing faces against
the piston. See Figure 3.

CAUTION

On 1992-1999 models, the threaded bushing
head must be installed between the rivet head
and the pad holder. On 1992 models, one of
the U-shaped notches on the outer bushing
flange must engage the rivet as shown. On
1993-1999 models, the U-shaped notch on
the outer bushing flange must engage the
rivet. If the bushing is positioned incorrectly,
the rivet will be damaged when the caliper
mounting screw, and pin are tightened. Refer
to

Figure 1

BRAKES

537

Spring clip

Pad holder

Pad

WARNING

The spring clip loop and the brake pad fric-
tion material must face away from the piston
when the pad holder is installed in the caliper.
Brake failure will occur if the brake pads are
assembled incorrectly.

21. Coat the lower mounting pin shoulder with high-tem-
perature bearing/brake grease (Dow Corning Moly 44 or
equivalent).

22. Install the caliper over the brake disc, making sure the
friction surface on each pad faces against the disc.

23. Align the two mounting holes in the caliper with the
slider mounting lugs.

24. Install a washer onto the upper mounting screw (A, Fig-
ure 2) and insert the screw through the slider lug and then
thread into the caliper bushing. Install the screw finger-tight.

25. Insert the lower mounting pin (B, Figure 2) through
the caliper and then thread into the slider lug. Tighten the
mounting pin finger-tight.

26. Tighten the lower mounting pin to 25-30 ft.-lb. (34-41
N•m).

27. Tighten the upper mounting screw to 25-30 ft.-lb.
(34-41 N•m).

28. Refill the master cylinder reservoir with DOT 5 sili-
cone-based brake fluid, if necessary, to maintain the correct
fluid level. Install the diaphragm and top cap (Figure 14).

29. While the motorcycle is stationary with the engine off,
squeeze the front brake lever several times to seat the pads
against the disc.

WARNING

Do not ride the motorcycle until the brakes
are operating correctly. If necessary, bleed
the brake as described in this chapter.

30. Bed the pads in gradually for the first 100 miles (160
km) of riding by using only light pressure as much as possi-
ble. Immediate hard application glazes the new friction
pads and reduces their effectiveness.

FRONT BRAKE PADS

(2000-2003 MODELS)

There is no recommended mileage interval for changing

the front brake pads. Pad wear depends on riding habits and
conditions. Frequently inspect brake pads for wear. In-
crease the inspection interval when the wear indicator
reaches the edge of the brake disc. After removal, measure
the thickness of each pad. Replace the pads if they are worn
to 0.062 in. (1.6 mm).

Always replace the front brake pads as a set. If equipped

with dual front calipers, replace both sets of pads.

538

CHAPTER SIXTEEN

FRONT BRAKE CALIPER (2000-2003 MODELS)

1. Inboard caliper

body

2. O-ring
3. Piston seal
4. Dust seal
5. Piston
6. Anti-rattle spring
7. Brake pad
8. Outboard caliper

body

9. Bridge bolt

10. Bleed valve
11. Pad pin

Do not disconnect the brake hose from the caliper for

brake pad replacement. Only disconnect the brake hose if
the caliper is going to be removed.

As the brake pads wear, the brake fluid level drops in the

reservoir and automatically adjusts for wear. Check brake
fluid level often.

Replacement

Refer to Figure 15.

1. Review

Brake Service

in this chapter.

2. Place a spacer between the brake lever and the throttle
grip, and secure it in place. If the brake lever is inadver-

tently applied, this will prevent the pistons from being
forced out of the cylinders. If the piston is pushed out of the
cylinder, the caliper must be reassembled as described in

Front Brake Caliper (2000-2003 Models)

in this chapter.

3. Clean the top of the master cylinder.
4. Remove the screws (A, Figure 16) securing the cover,
the cover (B) and diaphragm.

CAUTION

5. Use a shop syringe and remove about 50% of the brake
fluid from the reservoir. This prevents the master cylinder
from overflowing when the pistons are compressed for rein-
stallation. Do not drain more than 50% of the brake fluid or
air will enter the system. Discard the brake fluid properly.
6. Loosen the pad pins (Figure 17).

CAUTION

The brake disc is thin in order to dissipate
heat and may bend easily. When pushing
against the disc, support the disc adjacent to
the caliper to prevent damage to the disc.

7. Hold the caliper body from the outside and push it toward
the brake disc. This will push the outer pistons into the cali-
per bores to make room for the new brake pads. Constantly
check the reservoir to make sure brake fluid does not over-
flow. Remove fluid, if necessary, before it overflows. Install
the diaphragm and cover. Tighten the screws finger-tight.
8. Remove the caliper mounting bolts (Figure 18) and re-
move the caliper from the front fork.
9. Remove the pad pins (Figure 17).
10. Remove the inboard and outboard brake pads from the
caliper.
11. Check the brake pads for uneven wear or damage.
12. Remove rust or corrosion from the brake disc.
13. Clean the pad pins of corrosion or dirt.
14. Check the friction surface of the new pads for debris or
manufacturing residue. If necessary, clean them with an
aerosol brake cleaner.

NOTE

When purchasing new pads, check with the
parts supplier to make sure the friction com-
pound of the new pad is compatible with the
disc material. Remove roughness from the
backs of the new pads with a fine-cut file, then
thoroughly clean them.

NOTE

The pads are not symmetrical. The pad with
one tab (A,

Figure 19

) must be installed on the

inboard side of the left side caliper and on the

BRAKES

539

outboard side of the right side caliper. The pad
with two tabs (B,

Figure 19

) must be installed

on the outboard side of the left side caliper and
on the inboard side of the right side caliper.

15. Install the outboard pad (Figure 20). Hold the pad in
place against the anti-rattle spring and install both pad pins
(Figure 21) through the caliper and the outboard brake pad.
16. Install the inboard pad (Figure 22) into the caliper.
Hold the pad in place against the anti-rattle spring and push
both pad pins through the inboard brake pad and into the
caliper. Tighten the pad pins finger-tight.
17. Separate the brake pads (Figure 23) to allow room for
the brake disc.
18. Install the caliper onto the brake disc and install the
mounting bolts (Figure 18). Tighten the bolts to 28-38
ft.-lb. (38-52 N•m).
19. Tighten the pad pin bolts (Figure 17) to 180-204 in.-lb.
(20-23 N•m).
20. Remove the spacer from the front brake lever.
21. Make sure there is sufficient brake fluid in the master
cylinder reservoir. Top it off if necessary.
22. Pump the front brake lever several times to reposition
the brake pads against the brake disc.
23. Refill the master cylinder reservoir, if necessary, to
maintain the correct fluid level as indicated on the side of
the reservoir. Install the diaphragm and the top cover.
Tighten the screws to 6-8 in.-lb. (0.5-1 N•m).

WARNING

Do not ride the motorcycle until the brakes
are operating correctly. If necessary, bleed
the brake as described in this chapter.

24. Bed the pads in gradually for the first 100 miles (160
km) of riding by using only light pressure as much as possi-
ble. Immediate hard application glazes the new friction
pads and greatly reduces their effectiveness.

FRONT BRAKE CALIPER

(1986-1999 MODELS)

Review

Brake Service

in this chapter.

Removal

1. Remove the upper mounting screw and washer (A, Fig-
ure 24) and the lower mounting pin (B).
2. Lift the brake caliper off the brake disc.
3A. If the caliper is going to be disassembled for service,
perform the following:

NOTE

If the brake pads will be reused, mark each
pad so it can be reinstalled in its original po-
sition in the caliper.

a. Remove the brake pads as described in this chapter.

540

CHAPTER SIXTEEN

Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual - page 39