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Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Service Manual - page 13

sm03824

Outer caliper housing

Inner caliper housing

Crossover seal

O-ring

10.

Bleeder valve

Square seal (4)

11.

Wiper (4)

Bridge bolt

12.

Bridge bolt/pad pin

Piston (4)

13.

Anti-rattle spring (4)

Upper mounting bolt (long)

14.

Lower mounting bolt (short)

Brake pads (2)

Figure 2-48. Front Brake Caliper

If necessary, remove bleeder valve (10).

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)

See

Figure 2-49

and

Figure 2-50

. Remove pistons.

Place FRONT BRAKE CALIPER PISTON REMOVER
(Part No. HD-48649) (3) between caliper housings.

NOTE

Verify the hole in the tool (1) aligns with the crossover
holes (2) in the caliper housings.

Insert two bridge bolts (2) (metric) and tighten
securely.

If the bleeder valve was removed, install finger-tight.

Apply

low pressure

compressed air to banjo bolt hole

(1) to remove pistons from caliper bores. Listen for
all four pistons to "pop" against the tool.

Remove bridge bolts and remove tool.

Wiggle pistons from caliper bores to completely remove.

If necessary, remove pad springs from each piston.

Avoid leakage. Prevent damage to piston or piston bore.
Use non-metallic tools when servicing components.
(00529d)

See

Figure 2-51

. Remove and discard crossover seal (1)

from inside caliper housing.

Using a wooden toothpick (2), remove a wiper (3) and
square seal (4) from each caliper bore. Discard all
removed parts.

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2013 Softail Service: Chassis 2-41

sm03820

1. Hole in tool
2. Crossover hole in caliper housing

Figure 2-49. Installing Tool

sm03819

1. Banjo bolt hole-apply low-pressure air
2. Bridge bolt (2)
3. Brake caliper piston remover

Figure 2-50. Removing Pistons

sm03821

1. Crossover seal
2. Wooden toothpick
3. Wiper
4. Square seal

Figure 2-51. Wipers and Seals

CLEANING, INSPECTION AND REPAIR

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)

Clean all parts with denatured alcohol or DOT 4 BRAKE
FLUID. Do not contaminate with mineral oil or other
solvents. Wipe parts dry with a clean, lint-free cloth. Clear
drilled passages and bore with clean compressed air. Do
not use a wire or similar instrument to clean drilled pas-
sages.

Carefully inspect all components. Replace any parts that
appear damaged, worn, or corroded.

Check pistons for pitting, scratches or corrosion on
face and also on ground surfaces.

Inspect caliper piston bore. Do not hone bore. If bore
should show pitting or corrosion, replace caliper.

Inspect pad pin for grooving and wear. Measure the
pad pin diameter in an unworn area and then in the
area of any grooving or wear. If wear exceeds 0.015
in. (0.38 mm), replace both pins.

Always replace wipers, square seals and crossover
seal after disassembly.

HOME

2-42 2013 Softail Service: Chassis

If decal on outside housing is removed, scrape remaining
adhesive from surface with a razor blade.

Inspect brake pads and brake disc. See

1.16 BRAKE

PADS AND DISCS

ASSEMBLY

TORQUE VALUE

FASTENER

9.0-11.3 Nm

80-100

in-lbs

Brake caliper bleeder valve

38.0-51.5 Nm

28-38 ft-lbs

Brake caliper bridge bolt, front

20.3-22.6 Nm

15-16 ft-lbs

Brake bridge bolt/pad pin, front
caliper

NOTE

Do not use DOT 4 brake fluid for lubrication. Use of DOT 4
brake fluid will result in increased lever travel.

Lubricate the following parts prior to assembly using a
light coat of G.E. VERSILUBE #G322 L SILICONE
GREASE (marked "Piston Lube") from the service parts
kit. All other surfaces must be dry for assembly.

Lubricate nose radius and outside diameter of piston.
Apply lube to inside of caliper piston bores.

Apply lube to inside diameter of seals and wipers.

Avoid leakage. Prevent damage to piston or piston bore.
Use non-metallic tools when servicing components.
(00529d)

See

Figure 2-48

. Install a

new

square seal (3) and a

new

wiper (4) into each piston bore. Use a wooden toothpick
to aid installation, if needed.

See

Figure 2-52

. Install pad spring (2) in each piston.

Verify spring is securely installed in the groove in the
piston.

Turn the piston so the pad spring (2) is oriented as shown.
Carefully insert pistons, by hand, into bores of both caliper
housings. Press pistons squarely into place until they
bottom in the bores. If installation shows resistance,
remove piston and check that seals and wipers are prop-
erly installed.

Place a

new

crossover seal (1) on inside caliper housing.

Assemble caliper housings.

Install bleeder valve and tighten to 80-100

in-lbs

(9.0-

11.3 Nm).

Verify that

new

crossover seal is installed on inside

caliper housing.

See

Figure 2-48

. Mate inside and outside caliper

housings using bridge bolt (11) and upper mounting
bolt (long) (13) (metric).

Tighten bridge bolt to 28-38 ft-lbs (38.0-51.5 Nm).

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

NOTES

•

See

Figure 2-53

. Verify the pad spring tabs (1) on brake

pad engage the pad springs in the pistons.

•

If the directional tab (2) does not face down when caliper
is installed, brake noise may develop.

•

2011 and later Softail Models use a different front brake
pad than earlier models. The changes to the front brake
pad include an insulator plate and different friction material.
See an authorized Harley-Davidson dealer for the correct
replacement brake pads.

•

See

Figure 2-54

. Softail front brake pads can be identified

by a white marking on each brake pad.

Install

new

pads into caliper. The directional tab (2) must

face down when caliper is installed.

See

Figure 2-48

. Install pad pin/bridge bolt (12) (metric).

Tighten to 15-16 ft-lbs (20.3-22.6 Nm).

sm03827

1. Crossover seal
2. Pad springs

Figure 2-52. Front Caliper Pad Springs

HOME

2013 Softail Service: Chassis 2-43

sm04031b

1. Pad spring tabs
2. Directional tab
3. Front brake pad

Figure 2-53. Front Brake Pads

sm06990a

Figure 2-54. Softail Front Pad Indicator Markings

INSTALLATION

TORQUE VALUE

FASTENER

38.0-51.5 Nm

28-38 ft-lbs

Brake caliper, front, lower
mounting bolt

38.0-51.5 Nm

28-38 ft-lbs

Brake caliper, front, upper
mounting bolt

23.1-29.9 Nm

17-22 ft-lbs

Brake caliper, front, banjo bolt

See

Figure 2-55

. Attach caliper to fork leg.

Place caliper over brake disc with bleeder valve facing
upwards.

NOTE

If ABS equipped, install wheel speed sensor cable retainer
when installing caliper to front fork.

Loosely install upper mounting bolt (4) (metric) into
top hole on fork leg.

Install lower mounting bolt (5) (metric) into bottom
hole on fork leg. Tighten bottom mounting bolt to 28-
38 ft-lbs (38.0-51.5 Nm).

Final tighten the top mounting bolt to 28-38 ft-lbs
(38.0-51.5 Nm).

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

Lubricate

new

steel/rubber washers with DOT 4 BRAKE

FLUID. Connect the brake line (3) to caliper using two

new

steel/rubber washers (2) and banjo bolt (1). Tighten

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)

Bleed brake system. See

2.15 BLEEDING BRAKES

NOTE

Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.

sm04090b

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

Figure 2-55. Front Caliper

HOME

2-44 2013 Softail Service: Chassis

2.13

REAR BRAKE MASTER CYLINDER

GENERAL

If the rear brake feels spongy or excessive pedal travel exists
or the brake does not work at all, proceed to Inspection.

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)

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)

NOTES

•

Use only CCI #20 BRAKE GREASE to lubricate master
cylinder bores, pistons, primary cups and secondary cups.

•

Use only KS62F assembly grease on caliper pistons and
piston seals.

•

Use only G40M BRAKE GREASE on the caliper pins and
boots.

REMOVAL

See

Figure 2-61

. Remove fastener (1) and retainer (2).

See

Figure 2-60

. Remove banjo bolt (1) and two

steel/rubber washers (2) to disconnect brake line from
master cylinder. Discard washers.

Remove nut (4) to free assembly from mounting bracket.

Figure 2-62

. Remove cotter pin (4) and washer (5) from

clevis pin (6). Remove master cylinder assembly from
brake pedal.

If disassembling master cylinder, remove retaining ring
(3).

DISASSEMBLY

NOTE

Do not disassemble the cartridge body. The cartridge body
components are not sold separately, so if piston seal leakage
is evident, replace the entire cartridge body assembly.

Thoroughly clean exterior of master cylinder assembly
with denatured alcohol.

Stand master cylinder assembly upright on banjo sealing
surface. For best results, suspend reservoir over edge of
table. Be sure to lay down a clean shop cloth to protect
the sealing surface from damage.

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)

See

Figure 2-56

. Push down on large flat washer to com-

press spring. While holding the spring in a compressed
state, remove retaining ring from groove in clevis and then
carefully release spring. Discard retaining ring.

NOTE

See

Figure 2-63

. Pushrod/clevis/spacer washer (7) are a one-

piece assembly.

Remove the large flat washer (17), dust boot (12) and
spring (10) from pushrod/clevis/spacer washer (7) end of
cartridge body (2). Remove spring (10) and spring retainer
(11) from dust boot (12).

See

Figure 2-57

. Push on threaded end of cartridge body

to remove from reservoir adapter. Use hand pressure only.
Exercise care to keep cartridge body free of dirt and
grease.

See

Figure 2-63

. Carefully remove two O-rings (1) from

outside of cartridge body (2). Exercise caution to avoid
scratching O-ring grooves.

Remove small retaining ring (8) from pushrod end of
cartridge body. Assembly is spring loaded so be sure to
hold the parts together as retaining ring is removed.

Remove pushrod/clevis/spacer washer (7) from cartridge
body. Remove small retaining ring (8) from pushrod, if
attached. Discard retaining ring.

HOME

2013 Softail Service: Chassis 2-45

sm03174

Figure 2-56. Removing Clevis

sm03175

Figure 2-57. Removing Cartridge

CLEANING AND INSPECTION

Clean all metal parts, except the cartridge body assembly,
and blow dry with compressed air. Clean all rubber parts
using denatured alcohol.

Inspect the reservoir adapter bore for scratches. Replace
the reservoir if scratches are present.

Check the dust boot for cuts or tears. Replace as neces-
sary.

Inspect the threads on the cartridge body and pushrod.
Replace part if threads are damaged.

Inspect the spring for cracks or damaged coils. Replace
as necessary.

Inspect O-ring grooves on the cartridge body for dirt.
Carefully clean O-ring grooves using a soft cotton cloth
moistened with alcohol and allow to dry. Inspect O-ring
grooves for scratches. Replace cartridge body if grooves
are scratched.

Inspect the reservoir cover gasket for cuts, tears or general
deterioration. If gasket and/or sight glass replacement is
necessary, proceed as follows:

From inboard side, push sight glass toward top of
cover until free.

Pull rubber gasket from cover.

Fit nipple of

new

gasket into hole of cover aligning

gasket and cover through holes.

From bottom of gasket, push flat end of sight glass
through nipple until top of glass is flush with top of
gasket. Verify that glass is square in bore. If some
lubrication is necessary, use a small quantity of clean
brake fluid.

ASSEMBLY

See

Figure 2-63

. To install piston (5) in cartridge body (2),

proceed as follows:

Install small spring (3) into cartridge body (2) making
sure that spring is seated in counterbore.

Lightly lubricate primary cup (4) and O-ring (6) on
piston (5) with DOT 4 BRAKE FLUID.

Install piston (5) over spring (3).

Install

new

large retaining ring (9) in groove on

pushrod/clevis/spacer washer (7) side of cartridge body
(2).

Position

new

retaining ring (8) on pushrod between spacer

washer and clevis, or on clevis inboard of the retaining
ring groove.

HOME

2-46 2013 Softail Service: Chassis

sm03176

Figure 2-58. Compress Spring and Retaining Ring

See

Figure 2-58

. Stand cartridge body upright on banjo

sealing surface. Lay down a clean shop cloth to protect
the sealing surface from damage.

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)

Insert ball end of pushrod into piston cup. Pushing down
on pushrod to compress spring, fit captured spacer washer
into cartridge body. Further compressing spring as
necessary, install retaining ring positioned in step 3 in
groove of cartridge body bore.

Verify that retaining ring is completely seated in groove
and that pushrod rotates freely.

See

Figure 2-63

. Lubricate

new

O-rings (1) with DOT 4

BRAKE FLUID and carefully install in grooves on outside
of cartridge body (2).

Wipe bore of reservoir (18) adapter with DOT 4 BRAKE
FLUID.

Insert cartridge body (2) into reservoir adapter. Align tab
on adapter with slot on threaded end of cartridge. Use
hand pressure only. Cartridge body is fully installed when
reservoir adapter contacts large retaining ring.

10. See

Figure 2-59

. Stand master cylinder assembly upright

on banjo sealing surface. For best results, suspend
reservoir over edge of table. Be sure to lay down a clean
shop cloth to protect the sealing surface from damage.

11. Install spring over pushrod and cartridge body until it

contacts side of large retaining ring.

12. Place concave side of spring retainer over end of spring

fitting inside tabs in slot of clevis.

13. Slide dust boot over spring and spring retainer.

14. Place large flat washer on top of dust boot fitting inside

tabs in slot of clevis.

15. Push down on large flat washer to compress spring. While

holding spring in a compressed state, install

new

retaining

ring in groove of clevis.

16. Pull down dust boot as necessary to seat over lip on

reservoir adapter.

17. Rotate boot so that hole is at the bottom. Bottom is the

side opposite the index tab on reservoir adapter.

sm03179

Figure 2-59. Master Cylinder Assembly

INSTALLATION

TORQUE VALUE

FASTENER

40.7-54.2 Nm

30-40 ft-lbs

Rear master cylinder nut

23.1-29.9 Nm

17-22 ft-lbs

Rear master cylinder banjo
bolt

39.4-46.1 Nm

29-34 ft-lbs

Rear brake master cylinder
retainer fastener

See

Figure 2-62

. If master cylinder was disassembled,

install

new

retaining ring (3).

Install master cylinder assembly on brake pedal. Install
washer (5) and

new

cotter pin (4) on clevis pin (6).

See

Figure 2-60

. Fit collar on cartridge body into hole of

mounting

bracket.

Apply

LOCTITE

243

MEDIUM

STRENGTH THREADLOCKER AND SEALANT (blue) to
threads of nut (4). Install nut on cartridge body until finger
tight. Tighten to 30-40 ft-lbs (40.7-54.2 Nm).

Lubricate

new

steel/rubber washers (2) with DOT 4

BRAKE FLUID. Position

new

steel/rubber washers on

each side of brake line (3). Insert the banjo bolt (1) through
washers and fitting. Tighten to 17-22 ft-lbs (23.1-29.9 Nm).

See

Figure 2-61

. Install retainer (2) into position. Make

sure tab on retainer is in alignment hole (3). Install fastener
(1) and tighten to 29-34 ft-lbs (39.4-46.1 Nm).

HOME

2013 Softail Service: Chassis 2-47

sm03171

1. Banjo bolt
2. Steel/rubber washers (2)
3. Brake line
4. Nut

Figure 2-60. Rear Brake Control: Front Mount

sm06983

1. Fastener
2. Retainer
3. Alignment hole

Figure 2-61. Master Cylinder Retainer

Bleed brake system. See

2.15 BLEEDING BRAKES

NOTE

A sight glass enables the rider to visually check the brake fluid
level without removing the master cylinder cover. When the
reservoir is full, the sight glass is dark. As the fluid level drops,
the glass lightens up to indicate this condition to the rider.

HOME

2-48 2013 Softail Service: Chassis

sm03765

1. Rear brake pedal
2. Master cylinder reservoir
3. Retaining ring
4. Cotter pin
5. Washer
6. Clevis pin

Figure 2-62. Rear Brake Control: Rear Mount

HOME

2013 Softail Service: Chassis 2-49

sm03172

11.

Spring retainer

O-ring

12.

Cartridge body

Dust boot

13.

Clevis pin

Spring

14.

Primary cup

Flat washer

15.

Cotter pin

Piston

16.

O-ring

Retaining ring

17.

Washer

Pushrod, Clevis, Spacer washer (one piece
assembly)

18. Reservoir

19.

Retaining ring

Hex nut

9. Retaining ring
10. Spring

Figure 2-63. Rear Master Cylinder Assembly

HOME

2-50 2013 Softail Service: Chassis

2.14

REAR BRAKE CALIPER

REMOVAL

NOTE

If only replacing brake pads, do not remove rear brake caliper.
Should pad replacement be necessary, see

1.16 BRAKE PADS

AND DISCS

See

Figure 2-64

. Remove the banjo bolt (1) and both

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

Remove both the slider pin (3) and mounting bolt (4)
(metric). Remove caliper assembly from brake disc.

To remove rear caliper mount:

Remove axle from rear wheel. See

2.5 REAR

WHEEL

Lift rear caliper mount away from axle and rear fork.
Notch in caliper mount must clear tab on rear fork.

SM04091

1. Banjo bolt
2. Steel/rubber washers
3. Slider pin
4. Mounting bolt
5. Tab slot

Figure 2-64. Rear Caliper

DISASSEMBLY

TOOL NAME

PART NUMBER

BRAKE CALIPER PISTON REMOVER

HD-48648

See

Figure 2-65

. Remove pad pin (3) and brake pads (12).

If necessary, remove bleeder valve (4).

NOTE

If phenolic insulators (8) are loose, remove from pistons.

HOME

2013 Softail Service: Chassis 2-51

sm03836

Torque clip

Slider pin

10.

Bushing (upper)

Rear caliper mount

11.

Rubber bumper

Pad pin

12.

Bleeder valve with O-ring

Brake pads (2)

13.

Anti-rattle spring

Caliper housing

14.

Square seals (4)

Rubber boot

15.

Bushing (lower)

Piston (2)

16.

Phenolic insulator (available only in repair kit)

Mounting bolt

Figure 2-65. Rear Brake Caliper

When removing piston with compressed air, piston can
develop considerable force and fly out of caliper bore.
Keep hands away from piston to avoid possible injury.
(00530b)

NOTE

Phenolic insulators may be loose when the brake pads are
removed, or may loosen when the pistons are expanded from
their bores. If insulators are not damaged, they can be reused.

See

Figure 2-66

. Remove pistons.

Place BRAKE CALIPER PISTON REMOVER (Part
No. HD-48648) (3) into caliper housing. Install bolt
(2) only enough to hold tool in place.

NOTE

Tool retaining bolt (2) is used only to keep tool from slip-
ping out of the caliper during piston removal, and does
not need to be tight. Do not use a wrench to tighten.

If the bleeder valve was removed, install it finger-tight.

Apply

low pressure

compressed air to banjo bolt hole

(1) to remove pistons from caliper bores. Listen for
both pistons to "pop" against the tool.

Remove piston remover tool.

Wiggle pistons from caliper bores to completely remove.

HOME

2-52 2013 Softail Service: Chassis

Avoid leakage. Prevent damage to piston or piston bore.
Use non-metallic tools when servicing components.
(00529d)

See

Figure 2-67

. Using a wooden toothpick (1), remove

two square seals (2) from each caliper bore. Discard all
removed parts.

Pull anti-rattle spring (3) straight out to remove.

sm03834

1. Banjo bolt hole-apply low-pressure air
2. Remover retaining bolt
3. Brake caliper piston remover (Part No. HD-48648)

Figure 2-66. Removing Pistons

sm03833

1. Wooden toothpick
2. Square seal
3. Anti-rattle spring

Figure 2-67. Seals and Spring

CLEANING, INSPECTION AND REPAIR

HOME

2013 Softail Service: Chassis 2-53

Carefully inspect all components. Replace any parts that
appear damaged or worn.

Check pistons for pitting, scratches or corrosion on
face and also on ground surfaces.

Inspect phenolic insulators for damage.

Inspect caliper piston bore. Do not hone bore. If bore
should show pitting or corrosion, replace caliper.

Inspect pad pin for grooving and wear. Measure the
pad pin diameter in an unworn area and then in the
area of any grooving or wear. If wear exceeds 0.015
in. (0.38 mm), replace both pins.

See

Figure 2-65

. Inspect rubber boot (14) for cracks

and damage. Inspect bushing (15) for free movement.
Inspect bushing (2) for free movement or damage.

Always replace square seals after disassembly.

If decal on outside housing is removed, scrape remaining
adhesive from surface with a razor blade.

Inspect brake pads and brake disc. See

1.16 BRAKE

PADS AND DISCS

ASSEMBLY

TORQUE VALUE

FASTENER

9.0-11.3 Nm

80-100

in-lbs

Brake caliper bleeder valve

9.0-13.6 Nm

80-120

in-lbs

Brake pad pin, rear caliper

NOTE

Do not use DOT 4 BRAKE FLUID for lubrication. Use of DOT
4 BRAKE FLUID will result in increased lever travel.

Lubricate nose radius and outside diameter of piston.
Apply lube to inside of caliper piston bores.

Apply lube to inside diameter of square seals.

Avoid leakage. Prevent damage to piston or piston bore.
Use non-metallic tools when servicing components.
(00529d)

See

Figure 2-67

. Install two

new

square seals (2) into

each piston bore. Use a wooden toothpick (1) to aid
installation if needed.

Install anti-rattle spring (3). Verify it is oriented correctly.

Carefully insert pistons, by hand, into bores of caliper
housing. Press pistons squarely into place until they
bottom in the bores. If installation shows resistance,
remove piston and check that seals are properly installed.

See

Figure 2-65

. Install bleeder valve (4) (with O-ring) in

caliper housing, if removed, and tighten to 80-100

in-lbs

(9.0-11.3 Nm).

NOTE

Verify phenolic insulators (8) are in place before installing brake
pads.

Insert brake pads into caliper with friction material facing
opening for brake disc.

Install pad pin (3) and tighten to 80-120

in-lbs

(9.0-13.6

Nm).

NOTE

If pad pins do not fit, check the following:

•

You are using a set of pads, not two identical pads.

•

Anti-rattle spring orientation matches

Figure 2-65

REAR BRAKE LINE ROUTING

See

Figure 2-68

. When routing the rear brake line (3), make

sure it is placed over the pivot shaft (2) and held in place by
hose clip (1). 2010 model year and earlier brake lines are
routed under the pivot shaft.

sm06974

1. Hose clip
2. Pivot shaft
3. Brake line

Figure 2-68. Rear Brake Line Routing

INSTALLATION

TORQUE VALUE

FASTENER

21.7-27.1 Nm

16-20 ft-lbs

Brake caliper mounting bolt,
rear

23.1-29.9 Nm

17-22 ft-lbs

Rear caliper banjo bolt

Install rear axle and caliper mount if removed. Verify notch
in mount engages tab on rear fork. See

2.5 REAR WHEEL

See

Figure 2-65

. Verify torque clip (9) is in place in caliper

mount.

See

Figure 2-64

. Install caliper with pads on caliper mount.

Tighten slider pin (3) and mounting bolt (4) (metric) to 16-
20 ft-lbs (21.7-27.1 Nm). Verify tabs on brake pads engage
slot (5) in caliper mount.

HOME

2-54 2013 Softail Service: Chassis

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

Lubricate

new

steel/rubber washers with DOT 4 BRAKE

FLUID. Connect the brake line to caliper using two

new

washers (2) and banjo bolt (1). Tighten to 17-22 ft-lbs
(23.1-29.9 Nm).

Bleed brake system. See

2.15 BLEEDING BRAKES

NOTE

Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.

HOME

2013 Softail Service: Chassis 2-55

2.15

BLEEDING BRAKES

GENERAL

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)

Front brake hand lever and rear brake foot pedal must have a
firm feel when brakes are applied. If not, bleed system as
described.

PROCEDURE

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

BASIC VACUUM BRAKE BLEEDER

SNAP-ON BB200A

TORQUE VALUE

FASTENER

9.0-11.3 Nm

80-100

in-lbs

Brake caliper bleeder valve

1.4-1.7 Nm

12-15

in-lbs

Front master cylinder reservoir
cover screws

0.7-0.9 Nm

6-8

in-lbs

Rear master cylinder reservoir
cover screws, non-ABS
models

NOTES

•

For best results, use of BASIC VACUUM BRAKE
BLEEDER (Part No. Snap-On BB200A) or equivalent tool
is recommended, particularly if the brake system was
completely drained. If a vacuum brake bleeder is not
available, use the following procedure.

•

ABS models: To confirm that the brake systems are
properly connected and air is completely purged, install
master cylinder reservoir covers, connect motorcycle to
DIGITAL TECHNICIAN II (Part No. HD-48650) and perform
"ABS Service" procedure.

Remove bleeder valve cap. Install end of clear plastic
tubing over bleeder valve and place free end in a clean
container.

Position vehicle or handlebar so master cylinder reservoir
is level.

NOTES

•

Wrap a clean shop towel around the outside of the master
cylinder reservoir to protect paint from brake fluid spills.

•

Always clean master cylinder cover before removing.

Remove cover from master cylinder reservoir.

A plugged or covered relief port can cause brake drag or
lock-up, which could lead to loss of control, resulting in
death or serious injury. (00288a)

Add brake fluid as necessary. Verify proper operation of
the master cylinder relief port by actuating the brake pedal
or lever. A slight spurt of fluid will break the fluid surface
in the reservoir if internal components are working prop-
erly. Refer to

Table 2-15

Operate the brake lever or pedal to build hydraulic pres-
sure.

NOTE

Pay careful attention to fluid level in the master cylinder reser-
voir. Add fluid before it empties to avoid drawing air into the
brake lines.

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