Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Service Manual - page 12

2.8

SEALED WHEEL BEARINGS

INSPECTION

When lifting a motorcycle using a jack, be sure jack con-
tacts both lower frame tubes where down tubes and lower
frame tubes converge. Never lift by jacking on cross-
members, oil pan, mounting brackets, components or
housings. Failure to comply can cause serious damage
resulting in the need to perform major repair work. (00586d)

Raise the wheel with a suitable lifting device.

Turn the wheel through several rotations.

NOTE

If ABS equipped, keep magnetic base dial indicator as far away
from wheel speed sensor and ABS encoder bearing as pos-
sible, or damage will occur.

Check end play as follows:

See

Figure 2-23

. Mount a magnetic base dial indicator

to the brake disc. Set the indicator contact point on
the end of the axle.

Firmly push the wheel to one side and zero the dial
indicator gauge.

Firmly pull the wheel back as far as it will go and note
the reading of the dial indicator.

Repeat the procedure to verify the reading.

Replace the bearings if end play exceeds 0.002 in.
(0.051 mm), or if there is drag, rough rotation,
abnormal noise or anything unusual.

sm02234

Figure 2-23. Wheel Bearing Inspection (Front Wheel

Shown)

REMOVAL

TOOL NAME

PART NUMBER

25MM BEARING REMOVER (NON-
ABS)

HD-44060-10A

25MM BEARING REMOVER (ABS)

HD-44060-11A

WHEEL BEARING
INSTALLER/REMOVER

HD-44060C

Remove wheel. See

2.4 FRONT WHEEL

2.5 REAR

WHEEL

If present, remove hub plate from wheel on opposite side
of front brake disc.

NOTES

•

See

Figure 2-25

. Some wheel hubs may not provide

adequate support for the puller bridge. In these cases
center a used brake disc over the hub to support the puller
bridge while removing the bearings.

•

ABS equipped motorcycles use both a special encoder
bearing (greenish tan in color) on the primary brake disc
side. They use a standard bearing (black) on the opposite
side. Select 25MM BEARING REMOVER (ABS) (Part
No. HD-44060-11A) or 25MM BEARING REMOVER
(NON-ABS) (Part No. HD-44060-10A).

See

Figure

2-24

Obtain

WHEEL

BEARING

INSTALLER/REMOVER (Part No. HD-44060C) and
assemble using 25MM BEARING REMOVER (ABS) (Part
No. HD-44060-11A) or 25MM BEARING REMOVER
(NON-ABS) (Part No. HD-44060-10A) (6).

Sparingly apply GRAPHITE LUBRICANT to forcing
screw (1) to maintain smooth operation and prolong
service life.

Install nut (2), washer (3) and bearing (4) on screw.
Insert assembly through hole in bridge (5).

Drop ball bearing inside 25 mm collet (6). Fasten collet
and ball bearing to forcing screw.

Hold end of forcing screw and turn collet to expand edges
of collet.

See

Figure 2-26

. When expanded collet has gripped

bearing edges, hold end of forcing screw and turn the nut
to remove bearing from wheel.

Remove spacer from inside wheel hub.

Repeat procedure for opposite side bearing. Discard all
bearings upon removal.

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2013 Softail Service: Chassis 2-25

sm02235

1. Forcing screw
2. Nut
3. Washer
4. Bearing
5. Bridge
6. Collet with ball bearing inside

Figure 2-24. Removal Tool

SM03870

Figure 2-25. Brake Disk as Puller Aid

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2-26 2013 Softail Service: Chassis

sm02236

1. Forcing screw
2. Nut

Figure 2-26. Remove Bearing

INSTALLATION

TOOL NAME

PART NUMBER

WHEEL BEARING
INSTALLER/REMOVER

HD-44060C

NOTES

•

Install first bearing on primary brake disc side of hub, which
is identified by having one or two grooves cut into the disc
mounting surface.

•

Keep ABS encoder bearings away from magnetic fields
(such as magnetic parts trays, magnetic base dial indic-
ators, alternator rotors, etc.) or damage will occur.

•

ABS equipped motorcycles use a special encoder bearing
(greenish tan in color) on the primary brake disc side and
a standard bearing (black) on the opposite side.

Obtain WHEEL BEARING INSTALLER/REMOVER (Part
No. HD-44060C) and assemble.

Sparingly apply graphite lubricant to threads of
threaded rod to prolong service life and maintain
smooth operation.

See

Figure 2-27

. Place threaded rod through support

plate. Insert assembly through wheel.

See

Figure 2-28

. Place the

new

bearing (6) on rod

(1) with lettered side facing away from wheel center-
line. ABS bearing with greenish tan side against pilot
(5).

Install pilot (5), bearing (4), washer (3) and nut (2)
over rod.

Hold hex end of threaded rod (1) and turn nut (2) to install
bearing (6) into primary side of hub. Bearing will be fully
seated when nut can no longer be turned. Remove tool.

Install spacer inside wheel hub.

Reverse tool and install opposite side bearing until bearing
contacts inner spacer.

sm02237

Figure 2-27. Installation Tool Support Plate

sm02238

1. Threaded rod
2. Nut
3. Washer
4. Bearing
5. Pilot
6. Wheel bearing

Figure 2-28. Installing Bearing

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2013 Softail Service: Chassis 2-27

sm02239

1. Bridge, (Part No. HD-44060-5)
2. Steel ball, (Part No. 12547)
3. Forcing screw, (Part No. HD-44060-4)
4. Nut, (Part No. 10210)
5. Washer, (Part No. 12004)
6. Bearing, (Part No. 217801)
7. Lubricant, (Part No. J-23444A)
8. Collet, 3/4 in, (Part No. HD-44060-3A)
9. Collet (ABS), 25 mm, (Part No. HD-44060-11A)
10. Collet, 1.0 in, (Part No. HD-44060-7)
11. Collet, 25 mm, (Part No. HD-44060-10A)
12. Pilot, 1.0 in, (Part No. HD-44060-8)
13. Support plate, (Part No. HD-44060-1)
14. Pilot, 3/4 in, (Part No. HD-44060-6)
15. Threaded rod, (Part No. 280856)

Figure 2-29. Wheel Bearing Installer/Remover Components

NOTES

•

Parts 1-7 are common to removal and installation.

•

Parts 8-10 are used for removal only.

•

Parts 11-15 are used for installation only.

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2-28 2013 Softail Service: Chassis

2.9

TIRES

GENERAL

Use only Harley-Davidson specified tires. See a Harley-
Davidson dealer. Using non-specified tires can adversely
affect stability, handling or braking, which could result in
death or serious injury. (00024b)

Be sure tires are properly inflated, balanced, undamaged,
and have adequate tread. Inspect your tires regularly and
see a Harley-Davidson dealer for replacements. Riding
with excessively worn, unbalanced, improperly inflated,
overloaded or damaged tires can lead to tire failure and
adversely affect stability and handling, which could result
in death or serious injury. (00014b)

Always maintain proper tire pressure as specified in

Table 2-10

Do not load tires beyond GAWR specified in

Table 2-4

Table 2-5

. Underinflated, over-inflated or overloaded tires can

fail.

NOTES

•

Check runout on all cast or spoke wheels before installing
a new tire. See

2.7 CHECKING AND TRUING WHEELS

•

Store new tires on a horizontal tire rack. Avoid stacking
new tires in a vertical stack. The weight of the stack
compresses the tires and closes down the beads.

•

Inspect tires for punctures, cuts, breaks and wear at least
weekly.

•

See

Figure 2-30

. The tread wear indicator bars will appear

on tire tread surfaces when 1/32 in (0.8 mm) or less of
tread remains. Always replace tires before they reach the
tread wear indicator bars.

New tires are needed if any of the following conditions exist.
See

1.8 TIRES AND WHEELS

•

Tire wear indicator bars are visible on the tread surfaces.

•

Tire cords or fabric are visible through cracked sidewalls,
snags or deep cuts.

•

A bump, bulge or split in the tire.

•

Puncture, cut or other damage to the tire that cannot be
repaired.

sm02177b

1. Sidewall
2. Tread surface

Figure 2-30. Tread Wear Indicators (Typical)

REMOVAL

NOTE

Care must be taken when removing and installing tire to prevent
cosmetic damage to wheel. This is especially true with wheels
that feature painted surfaces.

Remove wheel from motorcycle:

Front wheel:

see

2.4 FRONT WHEEL, Removal

Rear wheel:

see

2.5 REAR WHEEL, Removal

Deflate tire.

NOTE

On tube type wheels, it is not necessary to completely remove
tire from rim to replace tube. Removing one side allows the
tube to be replaced and allows for inspection of tire.

Loosen both tire beads from rim flange. In most cases, a
bead breaker machine will be required to loosen the beads
from the rim.

Remove tire.

CLEANING, INSPECTION AND REPAIR

Clean the inside of tire and outer surface of tube.

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2013 Softail Service: Chassis 2-29

If rim is dirty or rusty, clean with a stiff wire brush.

Check wheels for lateral and radial runout before installing
a tire. See

2.7 CHECKING AND TRUING WHEELS

Inspect the tire for wear and damage.

Inspect tread depth. Replace worn tires.

Replace tube and rim seal prior to installing tire.

Replace punctured or damaged tires. In some cases, small
punctures in the tread area may be repaired from within
the removed tire by a Harley-Davidson dealer. Speed
should NOT exceed 50 mph (80 km/h) for the first 24 hours
after repair, and the repaired tire should NEVER be used
over 80 mph (130 km/h). Failure to follow this warning
could lead to tire failure and result in death or serious
injury. (00015b)

Repair tread on tubeless tires if puncture is 1/4 in (6.4 mm)
or smaller. Repairs must be made from inside the tire.

Always combine a patch and plug when repairing damaged
tires.

INSTALLATION

TORQUE VALUE

FASTENER

1.4-1.7 Nm

12-15

in-lbs

Valve stem nut

1.4-1.7 Nm

12-15

in-lbs

Valve stem nut

Harley-Davidson front and rear tires are not the same.
Interchanging front and rear tires can cause tire failure,
which could result in death or serious injury. (00026a)

Do not exceed manufacturer's recommended pressure to
seat beads. Exceeding recommended bead seat pressure
can cause tire rim assembly to burst, which could result
in death or serious injury. (00282a)

For tire pressures, see

1.8 TIRES AND WHEELS, Tires

Some tires have arrows molded into the tire sidewall. Mount
these tires with the arrow pointing in the direction of forward
rotation. The colored dot on the sidewall is a balance mark.
Located it aligned with the valve stem.

Tube Type Tires

Match tires, tubes, rim strips or seals, air valves and caps
to the correct wheel. Contact a Harley-Davidson dealer.
Mismatching can lead to tire damage, allow tire slippage
on the wheel or cause tire failure, which could result in
death or serious injury. (00023c)

NOTES

•

For correct tire and tube types, see

2.2 SPECIFICATIONS

•

Whenever a tube type tire is replaced, the tube should
also be replaced. Inner tubes should be patched only as
an emergency measure. Replace a damaged or patched
tube as soon as possible. Rim bands must be used on all
tube type laced wheels.

See

Figure 2-31

. On tube type laced wheels, verify that

no spokes protrude through nipples. Install a rim strip into
the rim well. Be sure to align the valve stem hole in rim
strip with valve stem hole in rim.

Install tube and tire.

sm02466

Figure 2-31. Installing Rim Strip

Tubeless Tires: Cast Wheels

Only install original equipment tire valves and valve caps.
A valve, or valve and cap combination, that is too long or
too heavy can strike adjacent components and damage
the valve, causing rapid tire deflation. Rapid tire deflation
can cause loss of vehicle control, which could result in
death or serious injury. (00281a)

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2-30 2013 Softail Service: Chassis

On tubeless cast wheels, replace damaged or leaking valve
stems.

See

Figure 2-32

. Install rubber grommet (5) on valve stem.

Insert valve stem into rim hole.

Install metal washer (4) and nut (3).

Tighten to 12-15

in-lbs

(1.4-1.7 Nm).

Install tire.

sm07581

1. Bolt-on valve stem
2. Snap-in valve stem
3. Nut
4. Metal washer
5. Rubber grommet

Figure 2-32. Tubeless Tire Valve Stems

Tubeless Tires: Laced Wheels

Do not use lubricants when installing rim seal. Lubricants
can cause rim seal slippage leading to rapid tire deflation,
which could result in death or serious injury. (00612b)

Install new seal before mounting tire. Riding motorcycle
without seal in place can sever valve stem causing rapid
air loss leading to the loss of control, which could result
in death or serious injury. (00622b)

See

Figure 2-33

Tubeless laced (spoked) rims are identified

by the word "TUBELESS" etched into the outside of the

rim and are manufactured to the MTM profile. A typical
identifier would be "TUBELESS 16M/CxMTM3.00 T DOT".

•

Do not install a rim seal and tubeless tire on a laced
rim that is not identified as such.

•

Do not install a tube in a tire mounted on a tubeless
laced rim.

•

Do not install a tire on a tubeless laced rim without
the rim strip and rim seal installed.

Failure to follow these guidelines could result in sudden
and unexpected loss of air pressure, resulting in loss of
control, serious injury, or death.

NOTES

•

On tubeless laced wheels, a damaged or leaking valve
stem requires replacement of the rim seal.

•

Always replace the rim strip and rim seal whenever the
tire is removed.

•

Do not use lubricant when installing rim strip and rim seal.
Use lubricant only when installing tire to rim.

•

Only install original equipment tubeless rim seals and valve
caps.

•

Place rim in a tire mounting fixture to ease rim strip and
seal installation.

See

Figure 2-34

. Install a

new

rim strip (2) and rim seal

(1).

Insert valve stem through the rim hole and secure with
nut. Tighten to 12-15

in-lbs

(1.4-1.7 Nm).

Install tire.

sm06835a

Figure 2-33. Tubeless Laced Wheel Identification

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2013 Softail Service: Chassis 2-31

sm07284

1. Rim seal
2. Rim strip
3. Wheel

Figure 2-34. Tubeless Wheel and Seal

CHECKING TIRE RUNOUT

Lateral Runout

Check tire pressure.

See

Figure 2-35

. Turn the wheel on the axle and measure

tire lateral runout from a fixed point to a smooth area on
the tire sidewall. Avoid measuring on raised letters or
vents.

Tire lateral runout should not exceed 0.090 in (2.29 mm).
If tire runout exceeds specification, remove tire from rim
and check rim lateral runout. See

2.7 CHECKING AND

TRUING WHEELS

If rim lateral runout is within specification, the tire is
at fault and must be replaced.

If rim lateral runout is not within specification, correct
by adjusting selected spokes on laced wheels or
replace cast wheels. See

2.7 CHECKING AND

TRUING WHEELS

Install the tire. Check tire lateral runout of replacement
tire.

sm01803

Figure 2-35. Checking Tire Lateral Runout

Radial Runout

Check tire pressure.

See

Figure 2-36

. Turn the wheel on the axle and measure

tire radial runout at the tread centerline.

Tire radial runout should not exceed 0.090 in (2.29 mm).
If tire runout exceeds this specification, remove tire from
rim and check rim radial runout.See

2.7 CHECKING AND

TRUING WHEELS

If rim radial runout is within specification, the tire is at
fault and must be replaced.

If rim radial runout is not within specification, correct
by adjusting selected spokes on laced wheels or
replace cast wheels. See

2.7 CHECKING AND

TRUING WHEELS

Install the tire. Check tire radial runout of replacement tire.

sm01804

Figure 2-36. Checking Tire Radial Runout

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2-32 2013 Softail Service: Chassis

WHEEL BALANCING

NOTE

Install tire after balancing. See See

2.4 FRONT WHEEL,

Installation

2.5 REAR WHEEL, Installation

Static vs Dynamic

Wheel balancing is recommended to improve handling. Balan-
cing wheels reduces vibration especially at high speeds.

Static balancing will produce satisfactory results for normal
highway speeds. Dynamic balancing can produce better results
for deceleration.

Weights

The maximum weight permissible to accomplish balance is 3.5
oz (99.2 g) (total weight applied to the rim). If more than 3.5
oz (99.2 g) of weight is required, rotate the tire 180 degrees
on the rim and again balance the assembly. Balance wheels
to within 0.5 oz (14 g).

All wheel weights currently supplied by Harley-Davidson are
made from zinc which is lighter than lead. The weight of each
zinc segment is 0.18 oz (5 g) as compared to 0.25 oz (7 g) for
lead. Weights are stamped for easy identification.

NOTES

•

If adding more than 1.5 oz (43 g) of weight at one location,
divide the amount so that half is applied to each side of
rim.

•

On cast wheels without a flat area near the bead, place
the weights crosswise through the opening.

See

Figure 2-38

. Place weights on a smooth surface of

the wheel rim such that centrifugal force will help keep
them in place. Make sure the area of application is com-
pletely clean, dry, and free of oil and grease.

NOTE

See

Figure 2-37

. When installing wheel weights, consider

cosmetics. Keep snaking (1) within 0.040 in (1.02 mm) (2) of
straight. Also keep the angle alignment of individual segments
(3) within 3 degrees.

Remove paper backing from the weight. Press firmly in
place and hold for ten seconds.

sm07192b

1. Snaking
2. Not to exceed 0.040 in (1.02 mm)
3. Not to exceed 3 degree

Figure 2-37. Weight Segment Alignment

sm06487

Cast (typical with flat bead area)

Laced steel

Laced profile

Cast (special with no flat bead area)

Figure 2-38. Wheel Weight Placement

HOME

2013 Softail Service: Chassis 2-33

2.10

VEHICLE ALIGNMENT

AXLE ALIGNMENT

TOOL NAME

PART NUMBER

AXLE ALIGNMENT PLUGS

HD-48856-A

TORQUE VALUE

FASTENER

129-142 Nm

95-105 ft-lbs

Axle nut, rear

Checking Axle Alignment

Only a Harley-Davidson dealer should perform vehicle
alignment. Improper alignment can adversely affect sta-
bility and handling, which could result in death or serious
injury. (00060a)

Check vehicle alignment according to following proced-
ures. Incorrect alignment can adversely affect stability and
handling, which could result in death or serious injury.
(00287a)

Verify

wheels

are

true

specifications.

See

2.7 CHECKING AND TRUING WHEELS

Check steering head bearing adjustment and adjust if
necessary. See

1.18 STEERING HEAD BEARINGS

Remove exhaust components as necessary.

See

Figure 2-39

. Insert alignment plugs (1, 2) from the

AXLE ALIGNMENT PLUGS (Part No. HD-48856-A) into
left and right ends of rear axle. Turn handle until plug is
firmly held in the axle.

See

Figure 2-40

. Fabricate an alignment tool using a piece

of 1/8 in (3.175 mm) diameter aluminum welding rod
approximately 20 in (508 mm) long:

Grind one end down to a blunt point (1).

Use pliers to bend rod at a 90 degree angle (3), 1.75
in (44.45 mm) from the blunt point.

Place a snug-fitting rubber grommet (2) on rod to act
as a slide measurement indicator.

Gauge distance between rear fork pivot bolt and rear axle
alignment plug center:

See

Figure 2-41

. Measure outer diameter of rear fork

pivot bolt and divide measurement by two. Using a
pencil, draw a line from two different directions to
mark an X.

See

Figure 2-42

. Place blunt point of alignment tool

(1) in the center of the X marked on the rear fork pivot
bolt (2).

Slide rubber grommet (3) along tool shaft until it aligns
with hole in center of alignment plug (4).

Without moving grommet, position alignment tool on
left side of rear fork.

Check measurements on both sides of vehicle. Left and
right measurements must be equal within 0.03125 in.
(0.79375 mm) on both sides of vehicle. Adjust if necessary.
See Adjusting Axle Alignment below.

sm03937

1. Alignment plug (left side)
2. Alignment plug (right side)
3. Alignment hole

Figure 2-39. Axle Alignment Plugs

sm05426

1. Blunt point
2. Rubber grommet
3. 1.75 in (44.45 mm)
4. 18 in (457 mm)

Figure 2-40. Axle Alignment Tool

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2-34 2013 Softail Service: Chassis

sm07509

Figure 2-41. Pivot Bolt Center Marking

sm07498

1. Axle alignment tool
2. Rear fork pivot bolt (marked with X)
3. Rubber grommet
4. Axle alignment plug

Figure 2-42. Checking Alignment Using Axle Alignment

Tool

Adjusting Axle Alignment

All but FXSB:

See

Figure 2-43

. Remove e-clip (1). Loosen

rear axle nut (2).

FXSB:

See

Figure 2-44

. Loosen rear axle nut (2).

On side of rear fork that has longer distance from pivot
bolt to axle center, turn nut on axle adjuster (3) counter-
clockwise to shorten distance. Adjust axle until left and
right side alignment measurements are equal.

NOTES

•

Keep axle adjuster mechanisms firmly seated (under ten-
sion) on each side of rear fork during wheel alignment
procedures above. Do so by applying moderate upward
force on lower span of drive belt. This tensions drive belt,
which holds rear axle forward against both adjuster
mechanisms.

•

Do not tighten rear axle nut or install new E-clip until after
checking drive belt deflection.

Verify drive belt deflection after aligning rear wheel. Adjust
if required. See

1.12 DRIVE BELT AND SPROCKETS,

Adjusting Belt Deflection

Do not exceed specified torque when tightening axle nut.
Exceeding torque can cause wheel bearings to seize during
vehicle operation, which could result in death or serious
injury. (00408e)

Tighten axle nut to 95-105 ft-lbs (129-142 Nm).

All but FXSB:

See

Figure 2-43

. Install e-clip.

Erase pencil marks on pivot shaft when complete.

Install exhaust components.

sm02594a

1. E-Clip
2. Axle nut
3. Axle adjuster

Figure 2-43. Axle Adjusters

smo3882

1. Retainer
2. Axle nut
3. Axle adjuster

Figure 2-44. Axle Adjusters: FXSB

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2013 Softail Service: Chassis 2-35

2.11

FRONT BRAKE MASTER CYLINDER

GENERAL

Do not use parts from single caliper repair kits (9/16 inch
bore) on dual caliper models. Likewise, do not use parts
from dual caliper repair kits (11/16 inch bore) on single
caliper models. Using incorrect parts can cause brake
failure, which could result in death or serious injury.
(00278a)

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 per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

Do not allow dirt or debris to enter the master cylinder
reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)

See

Figure 2-45

. Master cylinders designed for dual disc (two

caliper) operation have an 11/16 in. (17.5 mm) bore, while

those that are designed for single disc (one caliper) operation
have a 9/16 in. (14.3 mm) bore. The bore size is stamped on
the master cylinder assembly inboard of the handlebar clamp
bracket.

REMOVAL AND DISASSEMBLY

Drain brake fluid.

Open bleeder nipple cap on front brake caliper.

Install end of a length of clear plastic tubing over cal-
iper bleeder valve, while placing free end in a suitable
container.

Open bleeder valve about 1/2-turn.

Pump brake hand lever to drain brake fluid.

Close bleeder valve.

Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and master cylinder bore are clean and undamaged before
assembly. (00322a)

Remove bolt and two steel/rubber washers to disconnect
fitting of hydraulic brake line from master cylinder. Discard
washers.

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2-36 2013 Softail Service: Chassis

sm03169

12.

Site glass

Lubricant

13.

Wiper

Screw (2)

14.

Master cylinder reservoir

Piston cap

15.

O-ring

Pivot pin

16.

Bushing

Piston

17.

Primary cup

Brake hand lever

18.

Retaining ring

Spring

19.

Handlebar clamp

Flat side

20.

Shoulder

TORX screw and washer (2)

10.

21.

Gasket

Pin

22.

11.

O-ring groove

Cover

Figure 2-45. Front Brake Master Cylinder

See

Figure 2-45

. Loosen both switch housing clamp

screws. Remove the two T27 TORX screws with flat
washers (9) to detach the handlebar clamp (8) from the
master cylinder reservoir (14).

Remove retaining ring (18) from pivot pin groove at bottom
of master cylinder bracket.

Remove pivot pin (15) and brake hand lever (17).

Carefully remove wiper (2) with pick or similar tool.

Remove piston cap (3).

Remove piston (5) with O-ring (4) and primary cup (6).

Remove spring (7).

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2013 Softail Service: Chassis 2-37

10. Remove both screws (13), cover (11) and the cover gasket

(10).

CLEANING AND INSPECTION

Use denatured alcohol to clean brake system components.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even
after assembly. Deterioration of these components can
cause brake failure, which could result in death or serious
injury. (00291a)

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

Clean all parts with denatured alcohol or DOT 4 BRAKE
FLUID.

Wipe dry with a clean, lint-free cloth.

Clear drilled passages and bore with clean com-
pressed air.

NOTE

Do not use a wire or similar instrument to clean drilled passages
in bottom of reservoir.

Carefully inspect all parts for wear or damage. Replace
as necessary.

Inspect the piston bore in the master cylinder housing for
scoring, pitting or corrosion. Replace as necessary.

Carefully inspect the outlet port that mates with the brake
line fitting. As a critical sealing surface, replace the housing
if any damage is noted.

Carefully inspect the cover gasket for damage. Replace
as necessary.

ASSEMBLY AND INSTALLATION

TORQUE VALUE

FASTENER

6.8-9.0 Nm

60-80

in-lbs

Handlebar switch clamp screw

4.0-5.1 Nm

35-45

in-lbs

Handlebar switch housing
screw

23.1-29.9 Nm

17-22 ft-lbs

Brake caliper/master cylinder
banjo bolt

NOTE

Always reassemble the master cylinder using new parts from
the correct repair kit.

See

Figure 2-45

. Install O-ring (4) into groove on outboard

side of piston (5) (pin side).

Install primary cup (6) over lip on inboard side of piston
with closed side (smaller OD) contacting shoulder.

Coat piston bore of master cylinder reservoir with special
lubricant (1) supplied in the service parts kit. Also apply

the lubricant to OD of installed O-ring (4) and primary cup
(6).

Insert spring (7) into piston bore, seated against counter-
bore (recess) at bottom.

Slide piston over spring.

Install wiper (2) over piston cap (3) with flat side of wiper
contacting cap shoulder.

Fit piston cap over piston pin (5).

Press down on wiper until it contacts the counterbore.
Larger OD of wiper must be completely seated in groove
on outlet side of piston bore.

Install the master cylinder reservoir cover (11). Secure
with two screws, but do not tighten at this time.

10. Assemble brake hand lever (17) to master cylinder bracket.

From the top of the assembly, install pivot pin (15) through
bracket and hand lever.

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

11. Install

new

retaining ring (18) in pivot pin groove. Verify

that retaining ring is completely seated in groove.

12. See

Figure 2-46

. Position the brake lever/master cylinder

assembly inboard of the switch housing assembly, enga-
ging the tab (2) on the lower switch housing (1) in the
groove (3) at the top of the brake lever bracket (4).

13. Secure the handlebar clamp to master cylinder with two

screws (with flat washers). Position hand lever and controls
for rider comfort. Beginning with the top screw, tighten to
60-80

in-lbs

(6.8-9.0 Nm).

14. Tighten switch housing screws to 35-45

in-lbs

(4.0-5.1

Nm).

Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and caliper bore are clean and undamaged before
assembly. (00321a)

15. Start banjo bolt (with

new

steel/rubber washers) to secure

brake line fitting to master cylinder reservoir. Tighten banjo
bolt to 17-22 ft-lbs (23.1-29.9 Nm).

When any hydraulic brake component, line or connection
is loosened or replaced on an ABS motorcycle, Digital
Technician II must be used during the brake bleeding
procedure to verify all air is removed from the system.
Failure to properly bleed the brake system could adversely
affect braking, which could result in death or serious injury.
(00585c)

16. Bleed front brake system. See

2.15 BLEEDING BRAKES

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2-38 2013 Softail Service: Chassis

NOTE

The shelf life of an unopened bottle of DOT 4 brake fluid is one
year. The shelf life of an uncontaminated bottle that has been
opened and then resealed is one week.

sm07078

1. Switch housing assembly
2. Tab
3. Groove
4. Brake lever bracket

Figure 2-46. Attach Master Cylinder to Right Handlebar

Switches

HOME

2013 Softail Service: Chassis 2-39

2.12

FRONT BRAKE CALIPER

REMOVAL

NOTE

If only replacing brake pads, see

1.16 BRAKE PADS AND

DISCS

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 atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and caliper bore are clean and undamaged before
assembly. (00321a)

See

Figure 2-47

. Remove the banjo bolt (1) and both

steel/rubber washers (2) to detach front brake line (3) from
caliper. Discard washers.

Remove the upper (4) and lower (5) mounting bolts
(metric). Lift caliper upward to remove from brake disc.

sm04090b

1. Banjo bolt
2. Steel/rubber washer (2)
3. Front brake line
4. Upper mounting bolt (metric)
5. Lower mounting bolt (metric)

Figure 2-47. Front Caliper

DISASSEMBLY

TOOL NAME

PART NUMBER

FRONT BRAKE CALIPER PISTON
REMOVER

HD-48649

See

Figure 2-48

. Remove bridge bolt/pad pin (12) (metric),

brake pads (7) and bridge bolt (11) (metric) to separate
caliper housings (1, 8).

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2-40 2013 Softail Service: Chassis

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