Content .. 14 15 16 17 ..

Harley Davidson 2013 Sportster Models. Service Manual - page 16

sm01813a

11.

Bleeder nipple cap

Caliper mounting bracket

12.

Pad spring

Bleeder valve

13.

Brake pad (2)

Caliper pin boot

14.

Damper

Pad retainer (2)

15.

Brake pad set (includes item 20)

Mounting bracket bolt pin (do not remove)

16.

Caliper body

Piston

17.

Piston seal

Caliper bolt pin (do not remove)

18.

Caliper bushing boot

Dust seal

19.

Piston kit

Pad pin plug

10.

20.

Pad pin

Retainer clip (not sold separately)

Figure 2-102. Rear Brake Caliper Assembly: XL Models

HOME

2013 Sportster Service: Chassis 2-73

DISASSEMBLY

See

Figure 2-102

. Remove pad spring (2). Do not remove

bleeder valve (12) at this time.

See

Figure 2-103

. Install a discarded brake pad in the

caliper with the backing plate (4) facing the piston. Position
the brake pad so the friction material (3) is against the
back of the caliper, as shown.

Loosely install brake pad pin (2) to hold brake pad in place.

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)

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

Do not damage banjo bolt sealing surface or threads of banjo
bolt hole in brake caliper. Use an air nozzle with a rubber tip.

See

Figure 2-104

. Gently apply low pressure compressed

air to banjo bolt hole (3) to force piston from caliper bore.

Remove brake pad pin and brake pad from caliper.

See

Figure 2-102

. Remove piston (16) from caliper bore

by hand. If necessary, gently wiggle piston to completely
remove.

NOTE

A damaged piston bore will leak when reassembled. Do not
use metal objects to remove or install components in piston
bore. Prevent damage to piston, seal and bore by only using
a wooden toothpick when servicing caliper.

See

Figure 2-105

. Using a wooden toothpick (1), remove

dust seal (2) and piston seal (3) from caliper bore. Discard
seals.

See

Figure 2-102

. If necessary, remove bleeder valve

(12).

sm01453

1. Brake caliper
2. Brake pad pin
3. Brake pad friction material
4. Brake pad backing plate
5. Brake caliper mounting bracket

Figure 2-103. Preparing Caliper for Piston Removal

sm01454

1. Low pressure air nozzle
2. Brake caliper
3. Banjo bolt hole
4. Brake pad

Figure 2-104. Removing Piston (caliper removed from

mounting bracket)

HOME

2-74 2013 Sportster Service: Chassis

sm01455

1. Wooden toothpick
2. Dust seal
3. Piston seal

Figure 2-105. Caliper 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 piston bore with denatured alcohol.

Clean all rubber parts with DOT 4 BRAKE FLUID. Do not
contaminate with mineral oil or other solvents. Wipe parts
dry with a clean, lint free cloth.

Blow out drilled passages and piston bore with low pres-
sure compressed air from a clean air supply. Do not use
a wire or similar instrument to clean drilled passages.

Carefully inspect all components. Replace as necessary.

Check piston for pitting, scratching or corrosion on
outside surfaces.

Inspect caliper piston bore. Do not hone bore. If bore
shows 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 is more than
0.011 in (0.28 mm), replace pad pin.

Always replace all seals after disassembly.

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

Inspect brake pads and brake disc. Replace if necessary.

See

1.16 BRAKE PADS AND DISCS: XL MODELS

for specifications.

See

2.5 WHEELS

for brake disc replacement pro-

cedure.

LUBRICATING REAR CALIPER BOLT PINS
AND BOOTS

Apply approximately 0.4 g of G40M BRAKE GREASE
inside caliper bushing boot and caliper pin boot.

See

Figure 2-106

. Apply G40M BRAKE GREASE inside

boot lip (8) to prevent sticking between boots (3, 4) and
bolt pins (5, 6).

Insert mounting bracket bolt pin (6) into caliper bushing
boot (3).

HOME

2013 Sportster Service: Chassis 2-75

sm01459

1. Rear brake caliper
2. Caliper mounting bracket
3. Caliper bushing boot
4. Caliper pin boot
5. Bolt pin (caliper)
6. Bolt pin (mounting bracket)
7. Tapered shoulder
8. Boot lip

Figure 2-106. Assembling Rear Brake Caliper to Mounting

Bracket

ASSEMBLY

NOTE

Use ONLY KS62F assembly grease for lubrication. Use of DOT
4 brake fluid will result in increased brake pedal travel.

Lubricate the following parts prior to assembly using a
light coat of KS62F assembly grease from the service
parts kit. All other surfaces must be dry for assembly.

Nose radius of piston. See

Figure 2-107

All surfaces of piston seal and dust seal.

NOTE

A damaged piston bore will leak when reassembled. Do not
use metal objects to remove or install components in piston
bore. Prevent damage to bore by only using a wooden toothpick
when servicing caliper.

See

Figure 2-105

. Install a

new

piston seal (3) and a

new

dust seal (2) into piston bore.

Carefully insert piston by hand, nose radius first (see

Figure 2-102

), into caliper bore. If installation shows res-

istance, remove piston and check that seals are properly
installed and fully seated in grooves.

See

Figure 2-102

. Install bleeder valve (12) on caliper

housing if removed. Do not tighten bleeder valve at this
time.

See

Figure 2-108

. Install pad spring in channel. Press

firmly into place.

sm01456

Figure 2-107. Piston Nose Radius

sm01432

Figure 2-108. Rear Caliper Pad Spring

HOME

2-76 2013 Sportster Service: Chassis

INSTALLATION

TORQUE VALUE

FASTENER

9.8-14.7 Nm

87-130

in-lbs

Caliper to mouting bracket: XL
Models

19.6-24.5 Nm

15-18 ft-lbs

Caliper bolt pin: XL Models

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

14.8-19.6 Nm

131-173

in-lbs

Brake pad pin

2.0-2.9 Nm

18-25

in-lbs

Brake pad pin plug

See

Figure 2-109

. Before installing caliper, make sure that

retainer clip is properly installed on mounting bracket.

See

Figure 2-102

. Install rear caliper onto the mounting

bracket:

Apply a small amount of LOCTITE 272 HIGH
STRENGTH/HIGH

TEMPERATURE

THREAD-

LOCKER AND SEALANT (red/orange) to mounting
bracket bolt pin (5) threads.

Place the rear caliper assembly (6) onto the mounting
bracket (1). Using an open end wrench, thread
mounting bracket bolt pin into caliper mounting
bracket. Tighten to 87-130

in-lbs

(9.8-14.7 Nm).

Apply a small amount of LOCTITE 272 HIGH
STRENGTH/HIGH

TEMPERATURE

THREAD-

LOCKER AND SEALANT (red/orange) to threads of
caliper bolt pin (7).

Slide caliper bolt pin through front mounting hole in
caliper (6). Carefully insert bolt pin shaft into caliper
pin boot (3) in mounting bracket (1).

Screw bolt pin into caliper. Tighten to 15-18 ft-lbs
(19.6-24.5 Nm).

Install rear brake caliper and mounting bracket assembly
onto vehicle.

NOTE

Brake caliper housing has a positive stop for banjo fitting. When
tightening banjo bolt into brake caliper in the next step, rotate
banjo fitting clockwise until it contacts positive stop.

See

Figure 2-110

. Position a

new

washer (2) on each side

of hydraulic brake line (3) banjo fitting. Insert banjo bolt
(1) through washers and fitting. Thread bolt into caliper
housing. Tighten to 20-25 ft-lbs (27.1-33.9 Nm).

NOTE

Front brake pad sets cannot be used on rear brake calipers.

Insert brake pads into caliper with friction material on pad
facing brake disc. Curved portion of pad fits into recessed
area of caliper. Make sure brake pad front mounting tab
(fits into slot in caliper mounting bracket.

See

Figure 2-102

. Press brake pads (15) tightly up against

pad spring (2) and install pad pin (10). Tighten to 131-173

in-lbs

(14.8-19.6 Nm).

NOTE

If pad pin does not fit, check the following:

•

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

•

See

Figure 2-108

. Pad spring orientation must match.

•

Pad front mounting tabs must be fully seated in mounting
bracket slot.

•

Pads must be pushed tight up against pad spring before
pad pin is installed.

See

Figure 2-102

. Install pad pin plug (9). Tighten to 18-25

in-lbs

(2.0-2.9 Nm).

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)

NOTES

•

If DOT 4 BRAKE FLUID contacts painted surfaces,
IMMEDIATELY flush area with clear water.

•

Rear brake master cylinder reservoir must be in a level
position when filling and checking fluid level.

•

See

Figure 2-111

. Reservoir cover (2) may be removed

from rear brake master cylinder reservoir (1) to more easily
verify fluid level in reservoir.

See

Figure 2-111

. To remove reservoir cover, grasp cover

(2) and gently pull straight out from reservoir (1).

Remove rear brake master cylinder reservoir cap (5). Add
DOT 4 BRAKE FLUID to reservoir until fluid reaches upper
fluid level (3). Do not overfill reservoir. Do not reuse brake
fluid.

After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)

10. Bleed brake system. See

2.17 BLEEDING BRAKES

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)

HOME

2013 Sportster Service: Chassis 2-77

11. Verify proper operation of master cylinder relief port.

Press against rear brake caliper to push caliper piston
back into its bore. This pushes brake fluid back
through master cylinder and verifies that relief port is
not plugged.

Pump brake pedal until caliper piston pushes pads
against disc and pressure is returned to brake system.

12. Add DOT 4 BRAKE FLUID to reservoir until fluid reaches

upper fluid level.

13. Install reservoir cover if removed.

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

14. Test brake system.

Turn ignition switch ON. Pump brake pedal to verify
operation of stop lamp.

Test ride motorcycle at low speed. If brakes feel
spongy, bleed system again. See

2.17 BLEEDING

BRAKES

NOTE

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

sm01460

Figure 2-109. Retainer Clip

sm03594a

1. Banjo bolt
2. Sealing washer (2)
3. Rear brake line
4. Brake caliper
5. Caliper mounting bracket
6. Damper

Figure 2-110. Rear Caliper Assembly

sm01463

1. Rear brake master cylinder reservoir
2. Reservoir cover
3. Upper fluid level
4. Lower fluid level
5. Reservoir cap

Figure 2-111. Rear Brake Master Cylinder Reservoir

HOME

2-78 2013 Sportster Service: Chassis

2.15

REAR BRAKE CALIPER: XR 1200X

REMOVAL

NOTE

If only replacing brake pads, do not remove rear brake caliper.
See

1.17 BRAKE PADS AND DISCS: XR 1200X

NOTE

Damaged banjo bolt surfaces will leak when reassembled.
Prevent damage to seating surfaces by carefully removing
brake line components.

NOTE

If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY
flush area with clear water.

Position motorcycle on a suitable lift.

Place a suitable container under the rear caliper brake
line banjo fitting to catch any brake fluid that may leak out.
Do not reuse brake fluid.

NOTE

Dispose of brake fluid in accordance with local regulations.

Disconnect left shock absorber from rear fork. Rotate
shock absorber out of the way.

Loosen rear axle nut and turn adjuster nuts to allow the
rear wheel to move forward to the adjustment limit.

See

Figure 2-112

. Remove the banjo bolt (2) and both

washers (3) to detach rear brake line (1) from brake cal-
iper. Discard washers.

Remove mounting bolt (5) and bolt pin (6).

Remove caliper assembly.

sm05109a

1. Rear brake line
2. Banjo bolt
3. Washer (2)
4. Bleeder valve
5. Mounting bolt
6. Bolt pin

Figure 2-112. Rear Caliper Assembly

HOME

2013 Sportster Service: Chassis 2-79

sm05110a

11.

Pad pin

Caliper mounting bracket

12.

Piston

Pad pin plug

13.

Mounting bolt

Dust seal

14.

Piston seal

Boot

15.

Bushing

Pad spring

16.

Pad retainer

Bolt pin

17.

Boot

Brake pad

18.

Caliper housing

Damper

19.

Wear plate

Bleeder valve

10. Bleeder nipple cap

Figure 2-113. Rear Brake Caliper: XR 1200X

DISASSEMBLY

See

Figure 2-114

. Remove brake pad pin plug to expose

brake pad pin (1). Remove brake pad pin and pads (2).

See

Figure 2-115

. Remove pad spring (1).

Remove bushing (2) from boot (3). Remove boot from
mounting hole (4). Do not remove bleeder valve at this
time.

See

Figure 2-116

. Install a discarded brake pad (1) in the

caliper with the backing plate facing the piston. Position

the brake pad so the friction material is against the back
of the caliper, as shown.

Loosely install brake pad pin (2) to hold brake pad in place.

HOME

2-80 2013 Sportster Service: Chassis

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

Do not damage banjo bolt sealing surface or threads of banjo
bolt hole in brake caliper. Use an air nozzle with a rubber tip.

Gently apply low pressure compressed air to banjo bolt
hole (3) to force piston from caliper bore.

Remove brake pad pin and brake pad from caliper.

Remove piston from caliper bore by hand. If necessary,
gently wiggle piston to completely remove.

NOTE

See

Figure 2-117

. Using a wooden toothpick (1), remove

dust seal (2) and piston seal (3) from caliper bore. Discard
seals.

10. If necessary, remove bleeder valve.

sm05112

1. Pad pin (plug removed)
2. Brake pad

Figure 2-114. Pad Pin

sm05113

1. Pad spring
2. Bushing
3. Boot
4. Mounting hole

Figure 2-115. Spring, Bushing and Boot

sm05114

1. Discarded brake pad
2. Pad pin
3. Banjo bolt hole

Figure 2-116. Removing Piston: XR 1200X

HOME

2013 Sportster Service: Chassis 2-81

sm05115

1. Wooden toothpick
2. Dust seal
3. Piston seal

Figure 2-117. Caliper Seals

CLEANING, INSPECTION AND REPAIR

Clean piston bore with denatured alcohol.

Clean all rubber parts with DOT 4 BRAKE FLUID. Do not
contaminate with mineral oil or other solvents. Wipe parts
dry with a clean, lint free cloth.

Blow out drilled passages and piston bore with low pres-
sure compressed air from a clean air supply. Do not use
a wire or similar instrument to clean drilled passages.

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

Check piston for pitting, scratching or corrosion on
outside surfaces.

Inspect caliper piston bore. Do not hone bore. If bore
shows 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 is more than
0.011 in (0.28 mm), replace pad pin.

Always replace all seals after disassembly.

Inspect bushing boot and bolt pin boot for deterioration or
damage. Replace as necessary.

Inspect wear plate on caliper mount for wear. Replace as
necessary.

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

Inspect brake pads and brake disc. Replace if necessary.

See

1.17 BRAKE PADS AND DISCS: XR 1200X

for

specifications.

See

2.5 WHEELS

for brake disc replacement pro-

cedure.

ASSEMBLY

See

Figure 2-118

. If removed, install bushing boot (3) in

caliper.

Apply approximately 0.4 g of G40M BRAKE GREASE
inside caliper bushing boot (3).

Insert caliper bushing (2) into boot. Verify that the lips of
boot are engaged in grooves at either end of bushing.

Install pad spring (1) in caliper housing. Verify that the
spring is installed in the orientation shown.

NOTE

Use ONLY KS62F assembly grease for lubrication of internal
brake parts. Use of DOT 4 brake fluid will result in increased
brake pedal travel.

Lubricate the following parts prior to assembly using a
light coat of KS62F assembly grease from the service
parts kit. All other surfaces must be dry for assembly.

Nose radius of piston.

All surfaces of piston seal and dust seal.

NOTE

See

Figure 2-119

. Install a

new

piston seal (3) and a

new

dust seal (2) into piston bore.

HOME

2-82 2013 Sportster Service: Chassis

Carefully insert piston by hand, nose radius first, into cal-
iper bore. If installation shows resistance, remove piston
and check that seals are properly installed and fully seated
in grooves.

Install bleeder valve if removed. Do not tighten bleeder
valve at this time.

sm05122

1. Pad spring
2. Bushing
3. Boot

Figure 2-118. Assemble Caliper

sm05115

1. Wooden toothpick
2. Dust seal
3. Piston seal

Figure 2-119. Caliper Seals

INSTALLATION

TORQUE VALUE

FASTENER

19.6-24.5 Nm

14-18 ft-lbs

Rear caliper pin bolt

19.6-24.5 Nm

14-18 ft-lbs

Rear caliper mounting bolt

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

61-68 Nm

45-50 ft-lbs

Shock absorber mounting bolt

See

Figure 2-120

. If removed, install bolt pin boot (1).

Apply approximately 0.4 g of G40M BRAKE GREASE
inside bolt pin boot.

If removed, install wear plate (2) on mounting bracket.

See

Figure 2-121

. Apply a drop of LOCTITE 272 HIGH

STRENGTH/HIGH TEMPERATURE THREADLOCKER
AND SEALANT (red/orange) to threads of bolt pin (6).

Place rear caliper assembly onto mounting bracket. Install
bolt pin (6), being careful not to pinch or roll boot over.

See

Figure 2-122

. Verify that the lip of the boot (1) properly

engages the groove (2) in the bolt pin.

Tighten bolt pin to 14-18 ft-lbs (19.6-24.5 Nm).

See

Figure 2-121

. Install mounting bolt (5) and tighten to

14-18 ft-lbs (19.6-24.5 Nm).

NOTE

Brake caliper housing has a positive stop for banjo fitting. When
tightening banjo bolt into brake caliper in the next step, rotate
banjo fitting clockwise until it contacts positive stop.

Position a

new

washer (3) on each side of hydraulic brake

line (1) banjo fitting. Insert banjo bolt (2) through washers
and fitting and thread bolt into caliper housing. Tighten to
20-25 ft-lbs (27.1-33.9 Nm).

10. Install brake pads. See

1.17 BRAKE PADS AND DISCS:

XR 1200X, Brake Pad Replacement: Rear

11. Secure lower end of shock absorber to rear fork. Tighten

to 45-50 ft-lbs (61-68 Nm).

12. Adjust drive belt and check vehicle alignment. See

1.24 WHEEL ALIGNMENT

HOME

2013 Sportster Service: Chassis 2-83

NOTES

•

If DOT 4 BRAKE FLUID contacts painted surfaces,
IMMEDIATELY flush area with clear water.

•

Rear brake master cylinder reservoir must be in a level
position when filling and checking fluid level.

13. Remove rear brake master cylinder reservoir cap. Add

DOT 4 BRAKE FLUID to reservoir until fluid reaches upper
fluid level (3). Do not overfill reservoir. Do not reuse brake
fluid.

14. Bleed brake system. See

2.17 BLEEDING BRAKES

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)

15. Verify proper operation of master cylinder relief port.

Press against rear brake caliper to push caliper piston
back into its bore. This pushes brake fluid back
through master cylinder and verifies that relief port is
not plugged.

Pump brake pedal until caliper piston pushes pads
against disc and pressure is returned to brake system.

16. Add DOT 4 BRAKE FLUID to reservoir until fluid reaches

upper fluid level.

17. Test brake system.

Turn ignition switch ON. Pump brake pedal to verify
operation of stop lamp.

Test ride motorcycle at low speed. If brakes feel
spongy, bleed system again. See

2.17 BLEEDING

BRAKES

NOTE

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

sm05120

1. Bolt pin boot
2. Wear plate

Figure 2-120. Caliper Mount

sm05109a

1. Rear brake line
2. Banjo bolt
3. Washer (2)
4. Bleeder valve
5. Mounting bolt
6. Bolt pin

Figure 2-121. Rear Caliper Assembly

HOME

2-84 2013 Sportster Service: Chassis

sm05123

1. Boot
2. Bolt pin groove

Figure 2-122. Bolt Pin and Boot

HOME

2013 Sportster Service: Chassis 2-85

2.16

BRAKE LINES

FRONT BRAKE LINE

TORQUE VALUE

FASTENER

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

5.1-7.4 Nm

45-65

in-lbs

Brake line clamp screw, fork
bracket

13.6-19.0 Nm

120-168

in-lbs

Brake line clamp screw,
steering stem, XL Models

11-16 Nm

96-144

in-lbs

Brake line clamp screw,
steering stem, XR 1200X

27.1-33.9 Nm

20-25 ft-lbs

Brake line banjo bolt

Removal

NOTE

Dispose of brake fluid in accordance with local regulations.

Drain the brake fluid. See

2.17 BLEEDING BRAKES,

Procedure

Remove the brake line clamp screw from fork bracket.

XL Models:

Upper fork bracket

XR 1200X:

Lower fork bracket

Remove brake line clamp at steering stem under the lower
fork bracket.

Dual Disc Models:

Remove screw with captive

washer and clamp to remove brake line manifold.

Single Disc Models:

Remove screw with captive

washer and clamp.

NOTE

Damaged banjo bolt surfaces will leak when reassembled.
Prevent damage to seating surfaces by carefully removing
brake line components.

Remove the banjo bolt and sealing washers from the
master cylinder assembly. Discard sealing washers.

Remove the banjo bolt and sealing washers to detach the
brake line from the front brake caliper(s). Discard sealing
washers.

Inspect the brake line. Replace as necessary.

sm05497

1. XR 1200X
2. XL models

Figure 2-123. Front Brake Master Cylinder Identification

Installation

NOTES

•

See

Figure 2-123

. The XR 1200X and XL models are

equipped with different master cylinder housings. Do not
mix parts.

•

When tightening banjo bolt to the master cylinder or cal-
iper, verify the banjo fitting contacts the positive stop.

Route the brake line. See

2.16 BRAKE LINES, Front Brake

Line Routing

See

Figure 2-124

Figure 2-125

. Loosely install the

master cylinder banjo bolt (2) and fitting with

new

sealing

washers (1).

Loosely install the upper clamp (3) with the screw (4):

XL Models:

To the upper fork bracket.

XR 1200X:

To the lower fork bracket.

Loosely install the lower clamp.

Single Disc Models:

To the lower fork bracket stem

with screw with captive washer.

Dual Disc Models:

See

Figure 2-125

. Thread the

screw (5) with captive washer through the brake line
manifold (7) and guide (6) into the steering head stem.

Loosely install the banjo bolt and banjo fitting with

new

sealing washers to the brake caliper(s).

HOME

2-86 2013 Sportster Service: Chassis

Tighten the fasteners to specification:

Master cylinder banjo bolt to 20-25 ft-lbs (27.1-33.9
Nm)

Clamp-to-fork bracket to 45-65

in-lbs

(5.1-7.4 Nm)

XL Models:

brake line-to-steering stem clamp screw

to 120-168

in-lbs

(13.6-19.0 Nm)

XR 1200X:

brake line-to-steering stem clamp screw

96-144

in-lbs

(11-16 Nm)

Banjo bolt-to-brake caliper(s) to 20-25 ft-lbs (27.1-
33.9 Nm)

Fill and bleed brakes with

new

DOT 4 BRAKE FLUID. See

2.17 BLEEDING BRAKES, Procedure

Test ride motorcycle. Repeat brake bleeding, if necessary.

sm07199

1. Sealing washer
2. Banjo bolt
3. Clamp
4. Screw
5. Screw w/captive washer
6. Clamp
7. Grommet
8. Brakeline: XL 883L/N, XL 1200C/C ANV/X, XL

1200CP w/Pull Back

9. Brakeline: XL 1200V/CP/CB w/Mini-Ape
10. Brakeline: XL 1200CP/CA w/Drag Bar

Figure 2-124. Brakelines: Single Disc Models

HOME

2013 Sportster Service: Chassis 2-87

sm01814a

1. Sealing washer
2. Banjo bolt
3. Clamp
4. Screw
5. Screw
6. Guide
7. Brakeline manifold
8. Brakeline: XR 1200X
9. Brakeline: XL 883R

Figure 2-125. Brakelines: Dual Disc Models

FRONT BRAKE LINE ROUTING

Do not bend metal brake line. Bending brake line could
cause metal fatigue and brake failure, which could result
in death or serious injury. (00543b)

XL 883R

Fit the upper clamp to the metal fitting at the top of the
single metal tube section.

NOTE

The brake line on dual disc models self-aligns. It creates a gap
between the metal tubing section and the lower fork bracket.
Visually confirm the gap.

Route the brake line behind the handlebar and the fork
brackets.

Separate the two brake lines and route down to the cal-
ipers.

XL 883L/N, XL 1200X, XL 1200C/C ANV/CP
w/Pull Back

See

Figure 2-126

. Fit the upper and lower clamps to the

metal fittings at the ends of the metal tube section.

Route the brake line downward in front of the right side of
the handlebar and inward behind fork brackets.

Continue routing the brake line downward crossing to left
side of the vehicle under front fork lower bracket to the
brake caliper.

Single Disc Models:

See

Figure 2-127

. Adjust the location

of the brake line in the lower P-clamp until there is a 1/4
in (6.35 mm) gap between the brake line metal tubing and
the lower fork bracket pinch bolt.

sm07201

1. Upper P-clamp
2. Lower P-clamp

Figure 2-126. Brakeline Routing: XL 883L/N, XL 1200X, XL

1200C/C ANV/CP w/Pull Back

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2-88 2013 Sportster Service: Chassis

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