Harley Davidson Softail 2000-2005. Service manual

c. Position the right side spacer collar (Figure 25)

with the flange side facing the transmission case
and install it between the transmission case and the
swing arm.

d. Insert the pivot shaft (Figure 26) from the right side

through the frame pivot area, the swing arm bush-
ing, the right side spacer collar and the transmission
case.

e. Position the left side spacer collar (Figure 27) with

the flange side facing the transmission case and in-

stall it between the transmission case and the swing
arm.

f. Continue to push the pivot shaft through the left

side spacer collar, the swing arm bushing and left
side of the frame pivot area. Push the pivot shaft in
until it bottoms.

g. Make sure both spacer collars (Figure 17) are in

place.

h. Install the

marked hardened washer onto the pivot

shaft.

4. On the right side, secure the pivot shaft (Figure 15) to
keep it from rotating in the following step.
5. Apply ThreeBond No. 1360 (red) threadlocking com-
pound to the pivot shaft threads prior to installing the
flange nut.
6. On the left side, install the flange nut (Figure 13) and
tighten to 90-110 ft.-lb. (122-149 N•m).
7. Slowly raise and lower the swing arm to ensure ease of
movement. If binding occurs, repeat Step 6 and correct the
problem.
8. Install the shock absorbers as described in this chapter.
9. On California models, install the charcoal canister as
described in Chapter Seven.
10. Install the inner fender and hook it onto the frame
hook. Install the two bolts (A, Figure 14) securing the in-
ner fender and tighten securely.
11. Install the rear caliper as described in Chapter Thir-
teen.
12. Install the rear wheel and the belt guard as described
in Chapter Nine.
13. Remove the wooden blocks or floor jack from under
the transmission and engine assembly.
14. Install the exhaust system as described in Chapter
Seven.
15. On models so equipped, install both saddlebags as de-
scribed in Chapter Fourteen.

REAR SUSPENSION

475

Table 1 REAR SUSPENSION TORQUE SPECIFICATIONS

Item

ft.-lb.

in.-lb.

N•m

Rear axle nut

60-65

–

81-88

Shock absorber

Mounting bolt

115-130

–

156-176

Flange locknut

32-39

–

43–-53

Swing arm pivot bolt lock nut

90-110

–

122-149

CHAPTER THIRTEEN

BRAKES

This chapter includes repair and replacement proce-

dures for all brake system components.

Refer to Table 1 and Table 2 located at the end of this

chapter.

BRAKE SERVICE

WARNING

Do not use brake fluid labeled

DOT 5.1

This is a glycol-based fluid that is

not com-

patible

with silicone-based DOT 5. DOT 5

brake fluid is purple while DOT 5.1 is am-
ber/clear. Do not intermix these two differ-
ent types of brake fluid. It will lead to brake
component damage and possible brake fail-
ure.

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.

WARNING

When working on the brake system, do

not

inhale brake dust. It may contain asbestos,
which is a know carcinogen. Do

not

use

compressed air to blow off brake dust. Use
an aerosol brake cleaner. Wear a facemask

and wash thoroughly after completing the
work.

The disc brake system transmits hydraulic pressure

from the master cylinders to the brake calipers. This pres-
sure is transmitted from the caliper(s) to the brake pads,
which grip both sides of the brake disc(s) 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. Compensate for this by occasionally adding
fluid.

The proper operation of this system depends on a sup-

ply of clean brake fluid (DOT 5) and a clean work envi-
ronment when any service is being performed. Any
particle of debris that enters the system can damage the
components and cause poor brake performance.

Brake fluid is hygroscopic (easily absorbs moisture)

and moisture in the system reduces brake performance.
Purchase brake fluid in small containers and properly dis-
card small quantities that remain. Small quantities of fluid
will quickly absorb the moisture in the container. Only use
fluid clearly marked DOT 5. If possible, use the same
brand of fluid. Do not replace the fluid with a non-silicone
fluid. 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.

TE:

Ref

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is m

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info

rma

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ode

ls.

When adding fluid, punch a small hole into the edge of

the fluid container’s seal to help control the fluid flow.
This is especially important to prevent spills while adding
fluid to the small reservoirs.

Perform service procedures carefully. Do not use sharp

tools inside the master cylinders or calipers or on the pis-
tons. Damage to these components could cause a loss in
the system’s ability to maintain hydraulic pressure. If
there is any doubt about the ability to correctly and safely
service the brake system, have a professional technician
perform the task.

Consider the following when servicing the brake sys-

tem:

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

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

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

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

5. Dispose of brake fluid properly.

6. 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

chapter.
7. The manufacturer does not provide wear limit specifi-
cations for the caliper and master cylinder assemblies.
Use good judgment when inspecting these components or
consult a professional technician for advice.

FRONT BRAKE PAD REPLACEMENT

(FXSTS AND FLSTS MODELS)

There is no recommended mileage interval for chang-

ing the brake pads. Pad wear depends on riding habits and
conditions. Frequently check the 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 brake pad with a vernier caliper or
ruler, and compare measurements to the dimensions in
Table 1.

Always replace both pads in the caliper at the same time

to maintain even brake pressure on the disc. Do not dis-
connect the hydraulic brake hose from the brake caliper
for brake pad replacement. Only disconnect the hose if the
caliper assembly is going to be removed.

CAUTION

Check the pads more frequently when the
lining approaches the pad metal backing
plate. If pad wear is uneven for some rea-
son, the backing plate may come in contact
with the disc and cause damage.

NOTE

The brake disc and caliper are mounted on
the right side of the front wheel on FXSTS
models, on FLSTS models they are located
on the left side.

1. Read the information under

Brake Service

in this chap-

ter.
2. Park the motorcycle on a level surface.
3. To prevent the front brake lever from being applied,
place a spacer between the brake lever and the throttle grip
and secure it in place. Then if the brake lever is inadver-
tently squeezed, the piston will not be forced out of the cylin-
der.
4. To prevent the reservoir from overflowing while reposi-
tioning the piston in the caliper, perform the following:

a. On models so equipped, remove the master cylinder

chrome cover (Figure 1).

b. Remove the screws securing the cover (A, Figure 2),

and remove the cover (B) and diaphragm.

BRAKES

477

c. Use a shop syringe and remove about 50% of the

brake fluid from the reservoir. Do

not

drain more

than 50% of the brake fluid or air will enter the sys-
tem. Discard the brake fluid properly.

5A. On FXSTS models, perform the following:

a. Remove the cotter pin and washer (Figure 3) from the

caliper upper mounting bolt.

b. Gently push the caliper against the brake disc to push

the piston back into the caliper to make room for the
new brake pads.

c. Remove the caliper upper mounting bolt and washers

(A, Figure 4).

d. Remove the caliper lower mounting bolt (B, Figure

4).

e. Slide the brake caliper (C, Figure 4) off the brake disc.

5B. On FLSTS models, perform the following:

a. Remove the spring pin from the caliper upper mount-

ing bolt.

b. Remove the lower and upper caliper mounting bolts.

Do not lose the washer on the upper mounting bolt.

c. Slide the brake caliper off the brake disc.

NOTE

If the brake pads are going to be reused, mark
them so they can be reinstalled into their orig-
inal locations.

6. Remove the outboard pad, pad holder and spring clip as
an assembly (Figure 6).
7. Remove the bolt (A, Figure 5) and the pad retainer (B)
securing the inner pad to the caliper.
8. Remove the inboard pad (Figure 6) and the outboard pad
(Figure 7).
9. Push the outboard pad (A, Figure 8) free of the spring
clip (B) and remove it.
10. Check the brake pads (Figure 9) for wear or damage.
Measure the thickness of the brake pad friction material
(Figure 10). Replace the brake pads if they are worn to the
service limit in Table 1.

478

CHAPTER THIRTEEN

11. Check the friction surface of the new pads for any de-
bris or manufacturing residue. If necessary, clean them off
with an aerosol brake cleaner.

NOTE

When purchasing new pads, check with the
dealership 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 off with brake
cleaner.

12. Inspect the upper mounting bolt and the lower mounting
pin. Replace them if they are damaged or badly corroded.
13. Replace the pad retainer (Figure 11) if it is damaged.
14. Check the piston dust boot (Figure 12) in the caliper. If
the boot is swollen or damaged, or if brake fluid is leaking
from the caliper, remove and overhaul the caliper. Refer to

Front Brake Caliper (FXSTS

and

FLSTS Models)

in this

chapter.
15. Remove all corrosion from the pad holder.
16. Replace the spring clip if it is damaged or badly cor-
roded.
17. Check the brake disc for wear as described under

Brake Disc

in this chapter. Service the brake disc if neces-

sary.
18. Assemble the pad holder, spring clip and outboard
brake pad 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 14.

c. The outboard brake pad has an insulator pad mounted

on its backside (A, Figure 8).

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

the lower end of the pad rests inside the pad holder.

BRAKES

479

Push the upper end of the brake pad past the spring
clip and into the holder.

NOTE

Step 19 is not necessary if the piston was repo-
sitioned in Step 4.

19. After the installation of new brake pads, the caliper pis-
ton must be relocated into the caliper before the caliper is in-
stalled over the brake disc. This will force brake fluid back
up into the reservoir. To prevent the reservoir from overflow-
ing, perform the following:

a. Remove the screws (A, Figure 2) securing the cover

(B) and remove the cover and diaphragm.

b. Use a shop syringe and remove about 50% of the

brake fluid from the reservoir. Do

not

drain more

than 50% of the brake fluid or air will enter the sys-
tem. Discard the brake fluid properly.

CAUTION

Do not allow the master cylinder to overflow
during this step. Wash brake fluid off any
painted, plated, or plastic surfaces immedi-
ately as it will damage most surfaces it con-
tacts. Use soapy water and rinse completely.

c. Install the old outer brake pad into the caliper and

against the piston.

d. Slowly push the outer brake pad and piston back into

the caliper. Watch the brake fluid level in the master
cylinder reservoir. If necessary, siphon off fluid before
it overflows.

e. Remove the old brake pad.
f. Temporarily install the diaphragm and cover. Install

the screws finger-tight at this time.

20. Install the inner brake pad (Figure 15) into the caliper
from the inside surface. Push the pad into place.
21. Install the outer brake pad/pad holder assembly (Figure
16).

WARNING

The spring clip loop and the brake pad friction
material (

Figure 17

) must face away from the

piston when the pad holder is installed in the
caliper. Brake failure will occur if this assem-
bly is installed incorrectly.

22. Install the pad retainer (Figure 18) onto the backside of
the caliper, indexing the tabs into the caliper recesses (C,
Figure 5).
23. Install the bolt (A, Figure 5) through the pad retainer
into the backside of the inner brake pad. Tighten the bolt to
40-50 in.-lb. (5-6 N•m).
24A. On FXSTS models, perform the following:

480

CHAPTER THIRTEEN

a. Carefully slide the brake caliper onto the brake disc.

Align the bolt two mounting bolt holes with the
mounting holes on the caliper mounting bracket.

b. Coat the outside surface of the lower mounting bolt

with Dow Corning Moly 44 grease or an equivalent
prior to installation.

c. Install the caliper lower mounting bolt (Figure 19)

through the caliper mounting bracket and into the cali-
per. Tighten finger tight at this time.

d. Install the caliper upper mounting bolt and washers

(Figure 20) and screw it into the threaded bushing.
Tighten the bolt finger-tight at this time.

e. Tighten the upper and lower mounting bolts to the

specifications in Table 2.

f. Install the washer (Figure 21) and

new

cotter pin

onto the caliper upper mounting bolt. Bend the ends
of the cotter pin over completely (Figure 3).

24B. On FLSTS models, perform the following:

a. Coat the outside surface of the lower mounting bolt

with Dow Corning Moly 44 grease or an equivalent
prior to installation.

b. Install the caliper mounting plate and brake pad onto

the backside of the brake disc.

c. Install the brake caliper onto the brake disc.
d. Move the caliper mounting plate into position and

align the hole in the caliper mounting plate with the
raised boss on the brake caliper mounting bracket.
Make sure the spring clip is positioned correctly in the
brake caliper.

e. Install the upper bolt and washer through the brake

caliper mounting bracket and into the brake caliper.
Tighten finger-tight at this time.

f. Install the lower bolt through the caliper and into the

brake caliper mounting bracket. Tighten finger-tight at
this time.

g. Tighten the upper and lower mounting bolts to the

specifications in Table 2.

h. Install the spring pin onto the upper mounting bolt.

BRAKES

481

Spring clip

Pad holder

Pad

25. Refill the master cylinder reservoir with DOT 5 brake
fluid, if necessary, to maintain the correct fluid level. Install
the diaphragm, top cover (B, Figure 2) and tighten the
screws (A) to 6-8 in.-lb. (1 N•m).

26. Apply the front brake lever several times to seat the pads
against the disc.

WARNING

Do not ride the motorcycle until the front
brake is operating correctly with full hy-
draulic advantage. If necessary, bleed the
brakes as described in this chapter.

27. On models so equipped, install the master cylinder
chrome cover (Figure 1).

FRONT BRAKE PAD REPLACEMENT

(ALL MODELS EXCEPT FXSTS AND FLSTS)

There is no recommended mileage interval for chang-

Always replace both pads in the caliper at the same time

CAUTION

Check the pads more frequently when the
lining approaches the pad metal backing
plate. If pad wear is uneven for some rea-
son, the backing plate may come in contact
with the disc and cause damage.

1. Read the information under

Brakes Service

in this

chapter.

2. Park the motorcycle on level ground.

3. Place a spacer between the brake lever and the throttle
grip, and secure it in place. If the brake lever is inadver-
tently squeezed, this will prevent the pistons from being
forced out of the cylinders.

4. Clean the top of the master cylinder of all dirt and debris.

5. On models so equipped, remove the master cylinder
chrome cover (Figure 22).

6. Remove the screws securing the cover (A, Figure 23),
and remove the cover (B) and diaphragm.

7. Use a shop syringe and remove about 50% of the brake
fluid from the reservoir. This will prevent the master cyl-
inder from overflowing when the pistons are compressed
for reinstallation. Do

not

drain more than 50% of the

brake fluid or air will enter the system. Discard the brake
fluid properly.

CAUTION

Do not allow the master cylinder to over-
flow during Step 7. Wash brake fluid off any
painted, plated, or plastic surfaces immedi-
ately as it will damage most surfaces it con-
tacts. Use soapy water and rinse completely.

482

CHAPTER THIRTEEN

8. Loosen the pad pin bolts (Figure 24).

CAUTION

The brake disc is thin in order to dissipate
heat and may bend easily. When pushing
against the disc in the following step, sup-
port the disc adjacent to the caliper to pre-
vent damage to the disc.

9. Hold the caliper body from the outside and push it to-
ward the brake disc. This will push the outer pistons into
the caliper bores to make room for the new brake pads.

Constantly check the reservoir to make sure brake fluid
does not overflow. Remove fluid, if necessary, before it
overflows. Install the diaphragm and cover. Tighten the
screws finger-tight.
10. Remove the caliper mounting bolts (Figure 25) and
remove the caliper from the front fork.
11. Remove the pad pin bolts (Figure 24).
12. Remove the inboard and outboard brake pads from
the caliper.
13. Check the brake pads for wear or damage. Measure the
thickness of the brake pad friction material. Replace the
brake pads if they are worn to the service limit in Table 1.
14. Carefully remove rust or corrosion from the disc.
15. Thoroughly clean the pad pin bolts of corrosion or
road dirt.
16. Check the friction surface of the new pads for debris
or manufacturing residue. If necessary, clean them off
with an aerosol brake cleaner.

NOTE

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

Figure 26

) must be installed on

the inboard side of the left side caliper and
on the outboard side of the right side caliper.
The pad with two tabs (B,

Figure 26

) must

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

NOTE

The front and rear caliper brake pads are
identical with the exception of the FXSTD
models. The FXSTD rear brake pads have a
vertical slot cut into them. Do not inter-
change the rear brake pads with the front
brake pads.

17. Install the outboard pad (Figure 27). Hold the pad in
place against the anti-rattle spring and install both pad pin
bolts (Figure 28) through the caliper and the outboard
brake pad.
18. Install the inboard pad (Figure 29) into the caliper.
Hold the pad in place against the anti-rattle spring and
push both pad pin bolts through the inboard brake pad and
into the caliper. Tighten the pad pin bolts finger-tight.
19. Separate the brake pads (Figure 30) to allow room
for the brake disc.

BRAKES

483

20. Carefully install the caliper onto the brake disc and
install the mounting bolts (Figure 25). Tighten the bolts to
28-38 ft.-lb. (38-52 N•m).
21. Tighten the pad pin bolts (Figure 24) to 180-200
in.-lb. (20-30 ft.-lb.).
22. Remove the spacer from the front brake lever.
23. Make sure there is sufficient brake fluid in the master
cylinder reservoir. Top it off if necessary.
24. Pump the front brake lever several times to reposition
the brake pads against the brake disc.
25. 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. (1 N•m).

WARNING

Do not ride the motorcycle until the front
brake is operating correctly with full hy-
draulic advantage. If necessary, bleed the
brakes as described in this chapter.

FRONT BRAKE CALIPER

(FXSTS AND FLSTS MODELS)

NOTE

On FXSTS models, the brake disc and cali-
per are mounted on the right side of the front
wheel, on FLSTS models they are located on
the left side.

Removal (FXSTS Models)

Refer to Figure 31.

1. Remove the cotter pin and washer (Figure 32) from the
caliper upper mounting bolt.
2. Remove the caliper upper mounting bolt and washers (A,
Figure 33).
3. Remove the caliper lower mounting bolt (B, Figure 33).
4. Slide the brake caliper (C, Figure 33) off the brake disc.

NOTE

Step 5 is only necessary if the caliper is go-
ing to be serviced.

5. If the caliper assembly is going to be disassembled for
service, perform the following:

NOTE

If the brake pads are going to be reused, mark
them so they can be reinstalled into their orig-
inal locations.

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

b. Slowly apply the front brake lever to push the piston

part way out of the caliper assembly for ease of re-
moval during caliper service.

6. Drain the brake fluid from the front brake hose as de-
scribed under

Brake Hose and Line Replacement

in this

chapter.

7. Loosen the banjo bolt at the caliper (D, Figure 33). Re-
move the banjo bolt and the two washers.

8. Move the brake hose out of the way and place it in a plas-
tic bag.

484

CHAPTER THIRTEEN

9. If the front caliper is not going to be serviced, place it in a
reclosable plastic bag to keep it clean.

Installation (FXSTS Models)

Refer to Figure 31.

1. If the caliper was disassembled for service, install the
brake pads as described in this chapter.
2. Carefully slide the brake caliper (C, Figure 33) onto the
brake disc. Align the bolt two mounting bolt holes with the
bolt holes on the caliper mounting bracket.
3. Coat the outside surface of the lower mounting bolt with
Dow Corning Moly 44 grease or an equivalent prior to in-
stallation.
4. Install the caliper upper mounting bolt and washers (A,
Figure 33) and screw it into the threaded bushing. Tighten
the bolt finger-tight at this time.
5. Install the caliper lower mounting bolt (B, Figure 33)
through the caliper mounting bracket and into the caliper.
Tighten finger-tight at this time.
6. Tighten the upper and lower mounting bolts to the speci-
fications in Table 2.
7. Install the washer (Figure 34) and

new

cotter pin onto

the caliper upper mounting bolt. Bend the ends of the cot-
ter pin over completely (Figure 32).
8. Install the brake line onto the caliper with a

new

washer

on both sides of the brake line fitting, then secure the fit-
ting to the caliper with the banjo bolt (D, Figure 33).
Tighten the banjo bolt to 17-22 ft.-lb. (23-30 N•m). Make
sure the fitting seats against the caliper locating tabs.
9. Refill the master cylinder reservoir with DOT 5 brake
fluid, if necessary, to maintain the correct fluid level. Install
the diaphragm, top cover and tighten the screws to 6-8 in.-lb.
(1 N•m).
10. Apply the front brake lever several times to seat the pads
against the disc.
11. Bleed the brakes as described under

Bleeding the Sys-

tem

in this chapter.

WARNING

Do not ride the motorcycle until the front
brakes operate correctly with full hydraulic
advantage. If necessary, bleed the brakes as
described in this chapter.

Removal (FLSTS Models)

Refer to Figure 35.

1. Remove the spring pin from the caliper upper mounting
bolt.
2. Remove the lower and upper caliper mounting bolts. Do
not lose the washer on the upper mounting bolt.

3. Slide the brake caliper off the brake disc.

NOTE

Step 4 is only necessary if the caliper is go-
ing to be serviced.

4. If the caliper assembly is going to be disassembled for
service, perform the following:

NOTE

If the brake pads are going to be reused, mark
them so they can be reinstalled into their orig-
inal locations.

5. Remove the brake pads as described in this chapter.
6. Drain the brake fluid from the front brake hose as de-
scribed under

Brake Hose and Line Replacement

in this

chapter.
7. Loosen the banjo bolt at the caliper. Remove the banjo
bolt and the two washers.
8. Move the brake hose out of the way and place it in a
plastic bag.
9. If the front caliper is not going to be serviced, place it
in a reclosable plastic bag to keep it clean.

Installation (FLSTS Models)

Refer to Figure 35.

1. If the caliper was disassembled for service, install the
brake pads as described in this chapter.
2. Coat the outside diameter of the lower mounting bolt
with Dow Corning Moly 44 grease or an equivalent prior to
installation.
3. Install the caliper mounting plate and brake pad onto the
backside of the brake disc.
4. Install the brake caliper onto the brake disc.
5. Move the caliper mounting plate into position and align
the hole in the caliper mounting plate with the raised boss on
the brake caliper mounting bracket. Make sure the spring
clip is positioned correctly in the brake caliper.

486

CHAPTER THIRTEEN

6. Install the upper bolt and washer through the brake cali-
per mounting bracket and into the brake caliper. Tighten fin-
ger-tight at this time.
7. Install the lower bolt through the caliper and into the brake
caliper mounting bracket. Tighten finger-tight at this time.
8. Tighten the upper and lower mounting bolts to the speci-
fications in Table 2.
9. Install the spring pin onto the upper mounting bolt.

NOTE

Install new steel banjo bolt washers in Step 10.

10. If the brake line was removed, install it onto the caliper
with a

new

washer on both sides of the brake line fitting,

then secure the fitting to the caliper with the banjo bolt.
Tighten the banjo bolt to 17-22 ft.-lb. (23-30 N•m). Make
sure the fitting seats against the caliper.
11. Refill the master cylinder reservoir with DOT 5 brake
fluid, if necessary, to maintain the correct fluid level. Install

the diaphragm, top cover and tighten the screws to 6-8
in.-lb. (1 N•m).

12. Apply the front brake lever several times to seat the pads
against the disc.

WARNING

Do not ride the motorcycle until the front
brake operates correctly with full hydraulic
advantage.

13. Bleed the brakes as described under

Bleeding the Sys-

tem

in this chapter.

Disassembly (FXSTS and FLSTS Models)

Refer to Figure 36.

1. Partially remove the piston from the caliper as described
during caliper removal in this chapter.

488

CHAPTER THIRTEEN

FRONT BRAKE CALIPER (FXSTS AND FLSTS MODELS)

1. Bolt
2. Pad retainer
3. Brake pads
4. Retaining ring
5. Dust boot
6. Piston
7. Piston seal
8. Body
9. Bleed valve

10. O-ring
11. Lower mounting pin
12. Spring clip
13. Pin boot
14. Threaded bushing
15. Pad holder
16. Washer
17. Upper mounting bolt

WARNING

Compressed air will force the piston out of
the caliper under considerable force. Do not
block the piston by hand as injury will occur.

2. Insert a small screwdriver into the notched groove ma-
chined in the bottom of the piston bore (Figure 37). Then
pry the retaining ring (Figure 38) out of the caliper body.

3. If the piston did not come partially out of the caliper bore,
perform the following:

a. Place a rag and a piece of wood in the caliper (Figure

39). Keep fingers out of the way of the piston.

b. Apply compressed air through the brake hose port and

force the piston out of the caliper.

4. Remove the piston and dust boot assembly (Figure 40).
5. Remove the piston seal (Figure 41) from the groove in
the caliper body.
6. Pull the threaded bushing (A, Figure 42) out of the cali-
per, then remove the pin boot (B).
7. Remove the O-rings from the caliper body (Figure 43).

Inspection

Service specifications for the front caliper components are

not available. Replace worn, damaged or questionable parts.
1. Clean the caliper body and piston in clean DOT 5
brake fluid or isopropyl alcohol, and dry them with com-
pressed air.
2. Make sure the fluid passageway in the base of the pis-
ton bore is clear. Apply compressed air to the opening to
make sure it is clear. Clean it out, if necessary, with clean
brake fluid.
3. Inspect the piston seal groove in the caliper body for
damage. If it is damaged or corroded, replace the caliper
assembly.

BRAKES

489

1. Wooden block
2. Rag
3. Piston

4. Air hose
5. Caliper

4. Inspect the banjo bolt threaded hole in the caliper body.
If it is worn or damaged, clean it out with a metric thread
tap or replace the caliper assembly.
5. Inspect the bleed valve threaded hole in the caliper
body. If it is worn or damaged, clean it out with a metric
thread tap or replace the caliper assembly.
6. Inspect the bleed screw. Apply compressed air to the
opening and make sure it is clear. Clean it out, if neces-
sary, with clean brake fluid. Install the bleed valve and
tighten it to 80-100 in.-lb. (9-11 N•m).
7. Inspect the caliper body for damage.
8. Inspect the cylinder wall and piston (Figure 44) for
scratches, scoring or other damage.
9. If the brake caliper mounting bracket was removed, in-
spect the bracket (Figure 45) for cracks or damage. In-
spect the front axle bushing (Figure 46) for wear.

Assembly

1. A Harley-Davidson rebuild kit (part No. 44020-83) in-
cludes a piston seal (A, Figure 47), piston (B), dust boot (C)
and retaining ring (D).

NOTE

Never reuse an old dust boot or piston seal.
Very minor damage or age deterioration
can make the boot and seal ineffective.

2. Soak the new dust and piston seal in clean DOT 5
brake fluid.
3. Carefully install the

new

piston seal into the groove.

Make sure the seal is properly seated in its groove.
4. Install

new

O-rings into the caliper grooves.

5. Wipe the inside of the pin boot with Dow Corning
MOLY 44 grease. Then insert the boot into the bushing
bore with the flange end seating in the bore groove (Fig-
ure 48).
6. Insert the threaded bushing into the boot (Figure 49).

490

CHAPTER THIRTEEN

Harley Davidson Softail 2000-2005. Service manual - page 28