Harley Davidson Softail 2000-2005. Service manual

9. Inspect the threads in the bore for the banjo bolt. If they
are worn or damaged, clean them out with a thread tap or re-
place the master cylinder assembly.
10. Check the top cover and diaphragm for damage or de-
terioration.
11. If necessary, separate the cover from the diaphragm
as follows:

a. Pull straight up on the sight glass (Figure 92) and

remove it from the cover and diaphragm.

b. Separate the diaphragm from the cover.
c. The trim plate may separate from the cover.

Assembly

NOTE

When installing a new piston assembly, coat
all parts with the lubricant provided with
the Harley-Davidson parts kit. When in-
stalling existing parts, coat them with DOT
5 brake fluid.

NOTE

Make sure the new piston kit is for a single
front disc motorcycle.

CAUTION

The cover and diaphragm must be assem-
bled as described. If the sight glass is not in-

BRAKES

501

stalled correctly through the cover and
diaphragm neck, brake fluid will leak past
these components.

1. If the cover and the diaphragm were disassembled, as-
semble them as follows:

a. Install the trim plate (Figure 93) onto the cover if it

was removed.

b. Insert the neck of the diaphragm into the cover.

Press it in until it seats correctly and the outer edges
are aligned with the cover.

c. Push the sight glass (Figure 92) straight down

through the cover and the neck of the diaphragm
(Figure 94) until it snaps into place. The sight glass
must lock these two parts together to avoid a brake
fluid leak.

2. Soak the

new

cup, O-ring and piston assembly in clean

DOT 5 brake fluid for 15 minutes to make them pliable.
Coat the inside of the cylinder bore with clean brake fluid
prior to the assembly of parts.

CAUTION

When installing the piston assembly, do not
allow the cup to turn inside out as it will be
damaged and allow brake fluid leaks within
the cylinder bore.

3. Install the spring and piston assembly into the cylinder
(Figure 95). Push them in until they bottom in the cylin-
der (Figure 87).
4. Position the retainer with the flat side going on first,
and install the piston cap and retainer onto the piston end.
5. Push down on the piston cap (Figure 96). Hold it in
place and press the retainer down until it correctly seats in
the cylinder groove (A, Figure 86).
6. Make sure the bushing is in place in the hand lever
pivot area.
7. Install the hand lever (B, Figure 85) into the master
cylinder. Install the pivot pin and secure it with the snap
ring. Make sure the snap ring is correctly seated in the
pivot pin groove (A, Figure 85).
8. Slowly apply the lever to make sure it pivots freely.
9. Install the master cylinder as described in this chapter.

REAR BRAKE PAD REPLACEMENT

There is no recommended mileage interval for chang-

ing the brake pads. Pad wear depends on riding habits and
conditions. Frequently check the pads for wear. Increase
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.

502

CHAPTER THIRTEEN

1. Read

Brake Service

in this chapter.

2. Park the motorcycle on level ground.

3. Tie the end of the brake pedal to the frame. If the brake
pedal is inadvertently applied, this will prevent the piston
from being forced out of the cylinder.

4. On models so equipped, remove the right side saddlebag
as described in Chapter Fourteen.

5. Clean the top of the rear master cylinder of all dirt and de-
bris.

6. Remove the screws securing the cover, and remove the
cover (Figure 97) and diaphragm.

7. Use a shop syringe to 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.
8. Loosen the pad pin bolts.

CAUTION

Do not allow the master cylinder to over-
flow during Step 9. Wash brake fluid off
painted, plated, or plastic surfaces immedi-
ately as it will destroy most surfaces it con-
tacts. Use soapy water and rinse completely.

CAUTION

The brake disc is thin and easily damaged.
When pushing against the disc in the follow-
ing step, support the disc adjacent to the
caliper to prevent damage.

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 pad pin bolts (Figure 98).
11. Remove the inboard and outboard brake pads from
the caliper.
12. 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.
13. Carefully remove any rust or corrosion from the disc.
14. Thoroughly clean the pad pins of any corrosion or de-
bris.
15. Check the friction surface of the new pads for debris
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
compound 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.

NOTE

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

Figure 99

) must be installed on

the outboard side. The pad with two tabs (B

BRAKES

503

Figure 99

) must be installed on the inboard

side of the caliper.

NOTE

The rear and front 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 them with the front brake pads.

16. Install the outboard pad (Figure 100) into the caliper.
17. Hold the pad in place and install the pad pin bolts
(Figure 98) part way in to hold the outboard pad in place.
18. Install the inboard pad (Figure 101) into the caliper.
19. Push the pad pin bolts (Figure 98) through the in-
board pad and tighten them to 180-200 in.-lb. (20-23
N•m).
20. Make sure there is sufficient brake fluid in the master
cylinder reservoir. Top it off if necessary.
21. Untie the brake pedal from the frame and pump the
rear brake pedal to reposition the brake pads against the
brake disc. Roll the motorcycle back and forth. Continue
to pump the brake pedal as many times as it takes to refill
the cylinders in the caliper and correctly position the
brake pads against the disc.
22. 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 rear
brake is operating correctly with full hy-
draulic advantage. If necessary, bleed the
brakes as described in this chapter.

REAR BRAKE CALIPER

Removal/Installation

CAUTION

Do not spill brake fluid on the swing arm or
rear wheel. 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.

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

NOTE

By performing Steps 1b and 1c, compressed
air may not be necessary for piston removal
during caliper disassembly.

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

CAUTION

Do not allow the pistons to travel out far
enough to come in contact with the brake
disc. If this happens, the pistons may scratch
or gouge the disc during caliper removal.

b. Slowly apply the brake lever to push the pistons part

way out of the caliper assembly for ease of removal
during caliper service.

c. Loosen the brake hose banjo bolt (A, Figure 102).

504

CHAPTER THIRTEEN

100

101

d. Loosen the three body mounting bolts (B, Figure

102).

2. Loosen the banjo bolt (A, Figure 102) attaching the
brake hose to the caliper assembly.
3. Place the loose end of the brake hose in a reclosable
plastic bag to prevent the entry of debris and to prevent re-
sidual brake fluid from leading out.
4. Remove the rear wheel as described in Chapter Nine.
5. Remove the banjo bolt and sealing washers (A, Figure
102) attaching the brake hose to the rear caliper assembly.
6. Remove the rear caliper assembly (Figure 103) from
the swing arm.
7. If necessary, disassemble and service the caliper as-
sembly as described in this chapter.
8. If the rear caliper is not going to be serviced, place it in a
reclosable plastic bag to keep it clean.
9. Installation is the reverse of removal. Note the follow-
ing:

a. Install the caliper assembly onto the disc, being

careful not to damage the leading edge of the brake
pads.

b. Refer to Chapter Nine to complete the installation

of the rear axle.

c. Apply clean DOT 5 brake fluid to the rubber portions

of the

new

sealing washers prior to installation.

d. Install a

new

sealing washer on each side of the

brake hose fitting and install the banjo bolt (A, Fig-
ure 102). Tighten the banjo bolt to 17-22 ft.-lb
(23-30 N•m).

e. If disassembled, tighten the three body mounting

bolts (B, Figure 102) to 28-38 ft.-lb. (38-52 N•m).

f. Bleed the brakes as described under

Bleeding the

System

in this chapter.

WARNING

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

Disassembly

1. Remove the caliper and brake pads (Figure 104) as de-
scribed in this chapter.
2. Remove the three caliper body bolts (Figure 105)
loosened during the removal procedure.
3. Separate the caliper body halves. Remove the O-ring
seals (Figure 106). New O-ring seals must be installed
every time the caliper is disassembled.

NOTE

If the pistons were partially forced out of the
caliper body during removal, Steps 4-6 may
not be necessary. If the pistons or caliper
bores are corroded or very dirty, a small
amount of compressed air may be necessary
to completely remove the pistons from the
body bores.

4. Place a piece of soft wood or a folded shop cloth over
the end of the pistons and the caliper body. Turn the as-
sembly over and place it on the workbench with the pis-
tons facing down.

WARNING

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

5. Apply the air pressure in short spurts to the hydraulic
fluid passageway to force out the pistons. Repeat this for
the other caliper body half. Use a service station air hose if
compressed air is unavailable.

CAUTION

In Step 7, do not use a sharp tool to remove
the dust and piston seals from the caliper
cylinders. Do not damage the cylinder sur-
face.

BRAKES

505

103

102

6. Use a piece of wood or a plastic scraper to carefully
push the dust seal and the piston seal in toward the caliper
cylinder and out of their grooves. Remove the dust and
piston seals.
7. If necessary, unscrew and remove the bleed valve (Fig-
ure 107).
8. Inspect the caliper assembly as described in this sec-
tion.

Inspection

1. Clean both caliper body halves and pistons in clean
DOT 5 brake fluid or isopropyl alcohol and dry them with
compressed air.
2. Make sure the fluid passageways (Figure 108) in the
piston bores are clear by applying compressed air to the
openings. Clean them out, if necessary, with clean brake
fluid.
3. Make sure the fluid passageways (Figure 109) in both
caliper body halves are clear by applying compressed air
to the openings. Clean them out, if necessary, with clean
brake fluid.
4. Inspect the piston and dust seal grooves in both caliper
bodies for damage. If they are damaged or corroded, re-
place the caliper assembly.

506

CHAPTER THIRTEEN

104

106

105

REAR BRAKE CALIPER

1. Caliper body bolt
2. Pad pin bolt
3. Trim plate
4. Bleed valve
5. Cap
6. Piston seal
7. Dust seal
8. Piston

9. Anti-rattle spring

10. O-ring
11. Rubber bumper
12. Outboard caliper body
13. Brake pads
14. Inboard caliper body

5. Inspect the banjo bolt threaded hole in the outboard
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 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.
7. Inspect the bleed valve. Apply compressed air to the
opening and make sure it is clear. Clean it out if necessary
with clean brake fluid. Install the bleed valve and tighten
it to 80-100 in.-lb. (9-11 N•m).
8. Inspect both caliper bodies for damage. Check the in-
board caliper mounting bolt hole threads (Figure 110) for
wear or damage. Clean them with an appropriate size met-
ric tap or replace the caliper assembly.
9. Inspect the cylinder walls and pistons for scratches,
scoring or other damage.
10. Check the anti-rattle spring for wear or damage.

Assembly

WARNING

Never reuse old dust seals or piston seals.
Very minor damage or age deterioration
can make the seals ineffective.

1. Soak the new dust and piston seals in clean DOT 5
brake fluid.
2. Coat the piston bores and pistons with clean DOT 5
brake fluid.
3. Carefully install the new piston seals into the lower
grooves. Make sure the seals are properly seated in their
respective grooves.
4. Carefully install the new dust seals into the upper
grooves. Make sure all seals are properly seated in their
respective grooves.
5. Repeat Step 3 and Step 4 for the other caliper body
half.
6. Position the pistons with the open end facing out and
install the pistons into the caliper cylinders. Push the pis-
tons in until they bottom.
7. Repeat Step 6 for the other caliper body half. Make
sure all pistons are installed correctly.
8. Coat the

new

O-ring seals in DOT 5 brake fluid and in-

stall the O-rings into the inboard caliper half.
9. Install the anti-rattle spring (Figure 111) onto the boss
on the outboard caliper half.
10. Make sure the O-rings are still in place and assemble
the caliper body halves.
11. Install the three caliper body bolts (Figure 105) and
tighten them securely. They will be tightened to the speci-
fied torque after the caliper is installed on the rear disc.

BRAKES

507

107

108

109

110

12. Install a

new

rubber bumper (Figure 112) if it was re-

moved.
13. Install the bleed valve assembly (Figure 107) if it
was removed and tighten it to 80-100 in.-lb. (9-11 N•m).
14. Install the caliper and brake pads as described in this
chapter.
15. Tighten the three caliper body mounting bolts to
28-38 ft.-lb. (38-52 N•m).
16. Bleed the brakes as described under

Bleeding the Sys-

tem

in this chapter.

REAR MASTER CYLINDER

Removal

1. Remove the exhaust system as described in Chapter
Seven.
2. On models so equipped, refer to Chapter Fourteen and
perform the following:

a. Remove the right side saddlebag.
b. Remove the right side footboard.

3. At the rear brake caliper, perform the following:

a. Insert a hose onto the end of the bleed valve (Figure

113). Insert the open end of the hose into a container.

b. Open the bleed valve and operate the rear brake pedal

to drain the brake fluid. Remove the hose and close the
bleed valve after draining the assembly. Discard the
brake fluid properly.

4. Remove the screws securing the cover, and remove the
cover (Figure 97) and diaphragm.
5. Remove the banjo bolt and sealing washers (A, Figure
114) securing the brake hose to the front of the master cylin-
der cartridge body.
6. Remove and/or release clips or tie-wraps securing the
rear brake line to the chassis until there is only enough
slack in the brake line to allow the removal of the brake
line from the front of the master cylinder fitting.
7. Disconnect the rear brake line from the front of the
master cylinder. Place the loose end of the brake hose in a

508

CHAPTER THIRTEEN

111

112

113

114

115

reclosable plastic bag to prevent the entry of debris and to
prevent any residual brake fluid from leaking out.
8. Use a 1 1/8 in. open-end wench, remove the hex nut (B,
Figure 114) securing the front of the master cylinder car-
tridge assembly to the frame boss. Pull the master cylinder
free from the square hole in the frame boss.
9. Remove the cotter pin and washer from the clevis pin.
10. Withdraw the clevis pin (A, Figure 115) and disconnect
the master cylinder (B) from the rear brake pedal assembly.
Remove the master cylinder assembly from the frame.
11. If necessary, service the master cylinder as described in
this chapter. If the master cylinder is not going to be serviced,
place it in a reclosable plastic bag to keep it clean.

Installation

1. Install the master cylinder onto the rear brake pedal as-
sembly.
2. Install the clevis pin through the two parts, then install the
washer and

new

cotter pin. Bend the ends over completely.

3. Insert the front of the master cylinder through the hole
in the mounting bracket.
4. Apply

ThreeBond

TB1342

equivalent

threadlocking compound to the hex nut threads prior to in-
stallation. Install the hex nut (B, Figure 114) and tighten it
to 50 ft.-lb. (68 N•m).
5. Connect the rear brake line to the front of the master
cylinder cartridge body.

6. Lubricate the

new

steel/rubber washers on each side

with fresh DOT5 brake fluid.
7. Install a

new

steel/rubber washer on each side of the

brake hose banjo fitting. Insert the banjo bolt through the
washers and banjo fitting and thread it into the cartridge
body (A, Figure 114). Then tighten the banjo bolt to 17-22
ft.-lb. (23-30 N•m).
8. Secure the rear brake line to the chassis using tie-wraps
or new clips.
9. Bleed the brakes as described under

Bleeding the Sys-

tem

in this chapter.

10. On models so equipped, refer to Chapter Fourteen and
perform the following:

a. Install the right side footboard.
b. Install the right side saddlebag.

11. Install the exhaust system as described in Chapter Seven.

WARNING

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

Disassembly

Refer to Figure 116.

1. Clean the exterior master cylinder housing with clean
DOT 5 brake fluid or isopropyl alcohol and dry it.

BRAKES

509

116

REAR MASTER CYLINDER

1. Cotter pin
2. Washer
3. Clevis pin
4. Clevis
5. Washer
6. Rubber boot
7. Spring retainer
8. Spring
9. Snap ring

10. Washer
11. Pushrod
12. Cartridge rebuild kit
13. Body
14. Sight glass
15. Diaphragm
16. Cover
17. Screw
18. Hex nut
19. Sealing washer
20. Banjo bolt

2. Store the master cylinder components in a divided con-
tainer, such as a restaurant-size egg carton, to help main-
tain their correct alignment positions.

3. Remove the master cylinder cover and diaphragm if it is
still installed.

4. Compress the spring, rubber boot and washer.

NOTE

On 2003 models, the pushrod, clevis pin and
spacer washer are an integral component.

5. On 2000-2002 models, support the master cylinder in a
vise. Use a brass drift to carefully tap out the pushrod pin (A,
Figure 117) from the clevis. Separate the clevis (B) from the
pushrod.

6. Remove the washer, rubber boot, spring retainer and
spring (Figure 118).

7. Depress the pushrod (A, Figure 119) and remove the
snap ring (B).

8. Remove the pushrod (Figure 120).

9. Remove the piston assembly (A, Figure 121) and spring
(B) from the cartridge.

510

CHAPTER THIRTEEN

117

118

119

120

121

122

Inspection

1. Clean all parts in clean DOT 5 brake fluid or isopropyl
alcohol and dry them with compressed air. Replace worn
or damage parts as described in this section. It is recom-
mended that a new cartridge rebuild kit assembly be in-
stalled every time the master cylinder is disassembled.

2. Inspect the cartridge body cylinder bore surface (Fig-
ure 122) for signs of wear and damage. Do not hone the
cartridge bore to clean or repair it. If it is less than perfect,
replace the cartridge and/or the master cylinder reservoir.

3. Check the piston primary cup (A, Figure 123) and the
O-ring (B) for deterioration or damage.

4. Check the spring (A, Figure 124) for bending, unequally
spaced coils or corrosion.

5. Inspect the boot (B, Figure 124) for tears or deterioration.

6. Check the pushrod, washer and snap ring (Figure 125)
for bending, wear or damage.

7. Check the reservoir body (Figure 126) for corrosion or
other damage. Make sure the opening (Figure 127) in the
base is clear.

8. Check the reservoir cap and diaphragm (Figure 128) for
damage.

BRAKES

511

123

124

125

126

127

128

Assembly

1. Coat all parts with clean DOT 5 brake fluid.

2. Soak the primary cup, O-ring and piston assembly in
clean DOT 5 brake fluid for 15 minutes to make them pli-
able. Coat the inside of the cartridge bore with clean brake
fluid prior to the assembling the parts.

CAUTION

When installing the piston assembly, do not
allow the primary cup to turn inside out as it
will be damaged and allow brake fluid leaks
in the cartridge cylinder bore.

3. Install the spring (B, Figure 121) into the cartridge.

4. Position the piston assembly with the primary cup (A,
Figure 121) end going in first. Make sure the piston cup
does not tear as it passes through the bore entrance (Figure
129).

5. Turn the reservoir on its end on a shop cloth. Carefully
push the piston assembly into the cartridge with a Phillips
screwdriver. Push the piston assembly in, then let it move out
several times to check for ease of movement.

6. Position the pushrod onto the end of the piston (Figure
120) and push the piston into the cartridge. Hold the push rod
in place (A, Figure 119) and install the snap ring (B). Make
sure the snap ring is correctly seated in the cartridge groove.

7. Install the spring and spring seat (Figure 118) onto the
pushrod and cartridge.

8. Install the washer into the boot and push it all the way to
the end (Figure 130).

9. Install the boot (Figure 131) onto the pushrod and car-
tridge.

NOTE

On 2003 models, the pushrod, clevis pin and
spacer washer are all one part.

10. On 2000-2002 models, perform the following:

512

CHAPTER THIRTEEN

129

130

131

132

133

a. Install the clevis and tighten it against the pushrod un-

til the roll pin holes are aligned.

b. Install a

new

roll pin (Figure 132) and tap it into place

until it is flush.

11. Install the diaphragm and reservoir cover (Figure 133).

BRAKE HOSE AND LINE REPLACEMENT

A combination of steel and flexible brake lines connect the

master cylinder to the brake calipers. Banjo fittings and bolts
connect brake hoses to the master cylinder and brake cali-
pers. Steel washers seal the banjo fittings.

Replace a hose if the flexible portion is swelling, cracking

or damaged. Replace the brake hose if the metal portion
leaks or if there are dents or cracks.

Front Brake Hose Removal/Installation

A single combination steel/flexible brake hose (Figure

134) connects the front master cylinder to the front brake
caliper. When purchasing a new hose, compare it to the old
hose to make sure the length and angle of the steel hose por-
tion are correct. Install

new

banjo bolt washers at both

ends.

CAUTION

Do not spill brake fluid on the front fork or
front wheel. Wash brake fluid off painted,
plated, or plastic surfaces immediately as it
will damage most surfaces it contacts. Use
soapy water and rinse completely.

1. On models so equipped, refer to Chapter Fourteen and re-
move the windshield assembly.
2. Drain the front brake system as follows:

a. Connect a hose over the bleed valve (A, Figure 135).
b. Insert the loose end of the hose into a container to

catch the brake fluid.

BRAKES

513

134

FRONT BRAKE HOSE

1. Washer
2. Banjo bolt
3. Hose
4. Screw
5. Bracket
6. Washer
7. Washer

135

c. Open the bleed valve and apply the front brake lever

to pump the fluid out of the master cylinder and brake
line. Continue until the fluid is removed.

d. Close the bleed valve and disconnect the hose.
e. Dispose of the brake fluid. Never reuse brake fluid.

Contaminated brake fluid will cause brake failure.

3. Before removing the brake line assembly, note the brake
line routing from the master cylinder to the caliper. Note the
number and position of metal hose clamps and/or plastic ties
used to hold the brake line in place.
4. Remove any metal clamp or cut any plastic ties.
5A. On FXSTS and FLSTS models, perform the following:

a. Remove the bolt securing the brake hose and mount-

ing plate (Figure 136) to the lower portion of the rigid
fork.

b. Remove the bolt and washer securing the brake hose

and mounting plate (Figure 137) to the lower portion
of the rigid fork leg below the steering stem.

5B. On models other than FXSTS and FLSTS, remove the
bolt securing the brake hose and mounting plate (Figure
138) to the lower steering stem. On models so equipped, do
not lose the guide plate between the hose mounting plate and
the steering stem.
6. Remove the screw or nut securing the metal clamps
around the brake line. Spread the clamp and remove it from
the brake line.
7. Remove the banjo bolt and washers (B, Figure 135) se-
curing the hose to the brake caliper.
8. Remove the banjo bolt and washers (A, Figure 139) se-
curing the hose to the front master cylinder.
9. Cover the ends of the brake hose to prevent brake fluid
from leaking out.
10. Remove the brake hose assembly (B, Figure 139) from
the motorcycle.
11. If the existing brake hose assembly is going to be rein-
stalled, inspect it as follows:

a. Check the metal pipes where they enter and exit at the

flexible hoses. Check the crimped clamp for looseness
or damage.

b. Check the flexible hose portions for swelling, cracks

or other damage.

c. If wear or damage is found, replace the brake hose as-

sembly.

12. Install the brake hose,

new

sealing washers and banjo

bolts (Figure 134) in the reverse order of removal. Note the
following:

a. Install

new

sealing washers against the side of each

hose fitting.

b. Carefully install the clips and guides to hold the

brake hose in place.

c. Tighten the banjo bolts to 17-22 ft.-lb. (23-30 N•m).

514

CHAPTER THIRTEEN

136

137

138

139

d. Refill the front master cylinder with clean brake fluid

clearly marked DOT 5. Bleed the front brake system
as described in this chapter.

WARNING

Do not ride the motorcycle until the front
brakes operate correctly with full hydraulic
advantage.

Rear Brake Hose Removal/Installation

A single combination steel and rubber brake hose (Figure

140) connects the rear master cylinder to the rear brake cali-
per. The rear brake switch is installed in the rear brake hose.
When buying a new hose, compare it to the old hose. Make
sure the length and angle of the steel hose portion are correct.
Install

new

banjo bolt washers at both hose ends.

CAUTION

Do not spill brake fluid on the swing arm,
frame or rear wheel. Wash brake fluid off
any painted, plated or plastic surfaces im-
mediately as it will damage most surfaces it
contacts. Use soapy water and rinse com-
pletely.

1. Remove the exhaust system as described in Chapter
Seven.
2. On models so equipped, remove the right side saddlebag
as described in Chapter Fourteen.
3. Drain the hydraulic brake fluid from the rear brake sys-
tem as follows:

a. Connect a hose to the rear caliper bleed valve (Figure

141).

b. Insert the loose end of the hose in a container to catch

the brake fluid.

c. Open the caliper bleed valve and operate the rear

brake pedal to pump the fluid out of the master cylin-
der and brake line. Continue until all of the fluid is re-
moved.

d. Close the bleed valve and disconnect the hose.
e. Dispose of the brake fluid. Never reuse brake fluid.

Contaminated brake fluid will cause brake failure.

4. Before removing the brake line, note the brake line rout-
ing from the master cylinder to the caliper. Note the number
and position of the metal hose clamps, plastic clips and plas-
tic ties used to hold the brake line in place. The metal clamp
and plastic clips can be reused.

NOTE

To open the cable clips, insert a small screw-
driver into the gap at the side of the clip and
carefully rotate the screwdriver.

BRAKES

515

140

141

REAR BRAKE HOSE

1. Sealing washer
2. Banjo bolt
3. Rear brake hose/

brake line assembly

4. Hose clip
5. Hose clamp
6. Bolt
7. Bolt
8. Rear brake light switch

5. Open the cable clips on the lower frame tube. Refer to A,
Figure 142 and Figure 143.

6. At the rear brake light switch, cut the plastic tie securing
the rear brake light switch wires, voltage regulator wires and
the engine sensor harness to the frame lower tube.

7. Disconnect the electrical connector from the rear brake
switch (A, Figure 144).

8. Remove the bolt (B, Figure 144) securing the brake light
switch to the frame bracket.

9. Remove the banjo bolt and washers (B, Figure 142) se-
curing the hose to the brake caliper.

10. Remove the banjo bolt and washers (Figure 145) secur-
ing the hose to the master cylinder.

11. Carefully move the rear brake line assembly forward
and away from the rear swing arm bracket. Remove the
brake hose assembly from the motorcycle.

12. If the existing brake hose assembly is going to be rein-
stalled, inspect it as follows:

a. Check the metal pipe where it enters and exits the

flexible hose. Check the crimped clamp for looseness
or damage.

b. Check the flexible hose portion for swelling, cracks or

other damage.

c. If wear or damage is found, replace the brake hose.

13. If replacement is necessary, remove the brake light
switch from the rear brake hose fitting.

14. Installation is the reverse of removal. Note the follow-
ing:

a. Install and tighten the stoplight switch securely.

b. Install

new

sealing washers against the side of each

hose fitting.

c. Carefully install the clips and guides to hold the

brake hose in place.

d. Tighten the banjo bolts to 17-22 ft.-lb. (23-30 N•m).

e. Refill the master cylinder with clean brake fluid

clearly marked DOT 5. Bleed the rear brake system as
described in this chapter.

WARNING

Do not ride the motorcycle until the rear
brake is operating correctly with full hy-
draulic advantage.

BRAKE DISC

The brake discs are separate from the wheel hubs and

can be removed once the wheel is removed from the mo-
torcycle.

516

CHAPTER THIRTEEN

142

143

144

145

Harley Davidson Softail 2000-2005. Service manual - page 37