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Harley Davidson Sportster Models 2009. Service Repair Manual - page 21

sm01812

12.

Caliper bushing boot

Caliper bracket

13.

Caliper pin boot

Pad pin plug

14.

Pad pin

Screw (2)

15.

Bolt pin (caliper)

Caliper body

16.

Pad spring

Pad retainer (2)

17.

Insulator (2)

Piston (2)

18.

Piston seal (2)

Brake pad (2)

19.

Brake pad set (includes item 9)

Dust seal (2)

20.

Piston kit

Retainer clip (not sold separately)

10.

21.

Bleeder valve

Bolt pin (mounting bracket)

11. Bleeder nipple cap

Figure 2-83. Front Brake Caliper Assembly

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2-54 2009 Sportster Service: Chassis

sm01335

Brake caliper

Brake pad pin

Brake pad friction material

Brake pad backing plate

Figure 2-84. Preparing Caliper for Piston Removal

sm01336

Low pressure air nozzle

Brake caliper

Banjo bolt hole

Brake pad

Figure 2-85. Removing Pistons

sm01337

Wooden toothpick

Dust seal

Piston seal

Figure 2-86. 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)

See

Figure 2-83

. Wipe old lubrication from inside of caliper

pin boot (2) and caliper bushing boot (12) with a soft, clean
cloth.

Clean all other rubber parts with HARLEY-DAVIDSON
D.O.T. 4 BRAKE FLUID. Do not contaminate with mineral
oil or other solvents. Clean all metal parts with denatured
alcohol. Wipe parts dry with a clean, lint free cloth.

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)

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.

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2009 Sportster Service: Chassis 2-55

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

Check pistons (17) for pitting, scratching or corrosion
on outside surfaces.

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

Inspect pad pin (14) 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.

Inspect caliper bolt pin (4). If damaged or excessively
worn, replace brake caliper assembly.

Inspect caliper bushing boot and caliper pin boot. If
worn or damaged, replace.

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

1.9 BRAKE PADS AND DISCS: XL MODELS

for

specifications.

See

2.4 WHEELS

for brake disc replacement pro-

cedure.

ASSEMBLY

NOTE

Use ONLY KS62F assembly grease for lubrication. Use of
D.O.T. 4 brake fluid will result in increased brake lever 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 pistons. See

Figure 2-87

All surfaces of piston seals and dust seals.

NOTE

Damaged piston bores will leak when reassembled. Do not
use metal objects to remove or install objects in piston bores.
Prevent damage to bores by only using a wooden toothpick
when servicing calipers.

See

Figure 2-86

. Install a new piston seal (3) and a new

dust seal (2) into each piston bore.

Carefully insert pistons by hand, nose radius first (see

Figure 2-87

), into caliper bores. If installation shows resist-

ance, remove piston(s) and check that seals are properly
installed and fully seated in grooves.

See

Figure 2-83

. Install bleeder valve (10) on caliper

housing if removed. Tighten bleeder valve to 35-61 in-lbs
(4.0-6.9 Nm).

See

Figure 2-88

. Place caliper housing on workbench as

shown. Install pad spring in channel. Press firmly into
place.

sm01338

Figure 2-87. Piston Nose Radius

sm01444

Figure 2-88. Front Caliper Pad Spring

LUBRICATING FRONT CALIPER BOLT PINS
AND BOOTS

See

Figure 2-89

. Apply approximately 0.4 g of G40M

BRAKE GREASE inside caliper bushing boot (3) and cal-
iper pin boot (4).

See

Figure 2-90

. Apply G40M BRAKE GREASE inside

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

Assemble brake caliper and mounting bracket, carefully
sliding bolt pins into boots. Slide brake caliper all the way
onto mounting bracket until boot lips fit over tapered
shoulders (7) of bolt pins.

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2-56 2009 Sportster Service: Chassis

sm01445

Front brake caliper

Caliper mounting bracket

Caliper bushing boot

Caliper pin boot

Caliper bolt pin

Bracket bolt pin

Figure 2-89. Lubricating Caliper Boots and Pins

sm01446

Front brake caliper

Caliper mounting bracket

Caliper bushing boot

Caliper pin boot

Caliper bolt pin

Bracket bolt pin

Tapered shoulder

Boot lip

Figure 2-90. Assembling Front Brake Caliper and Mounting

Bracket

INSTALLING BRAKE PADS IN CALIPER

NOTE

The front left and front right (not present on all models) calipers
do NOT use the same exact brake pad set as the rear brake
caliper.

See

Figure 2-91

. Insert one set of brake pads (1) into

caliper with friction material on pad facing opening for
brake disc. Curved portion of pad fits into recessed area
of caliper. Make sure brake pad front mounting tab (2) fits
into slot (5) in caliper mounting bracket (4).

See

Figure 2-83

. Press brake pads (8) tightly up against

pad spring (16) and install pad pin (14). 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.

•

Pad spring orientation must match

Figure 2-88

•

See

Figure 2-91

. Pad front mounting tabs (2) must be fully

seated in mounting bracket slot (5).

•

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

See

Figure 2-83

. Install pad pin plug (13). Tighten to 18-25

in-lbs (2.0-2.9 Nm).

sm01447

Brake pad

Front mounting tab

Pad pin hole

Front caliper mounting bracket

Slot

Figure 2-91. Front Brake Pads

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2009 Sportster Service: Chassis 2-57

INSTALLATION

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)

NOTE

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

If servicing a vehicle with a single front brake caliper,
advance to the next step. On models with dual front
brakes, align calipers to brake discs.

Tighten axle nut to 60-65 ft-lbs (81-88 Nm).

Loosen axle pinch screw nut.

Position right fork leg against bearing spacer. Tighten
axle pinch screw to 21-27 ft-lbs (28.5-36.6 Nm) and
withdraw drill bit.

See

Figure 2-92

. Place brake caliper (4) with mounting

bracket (5) over brake disc with bleeder valve (8) facing
upwards. Install mounting bolts (6) into mounting holes on
fork leg. Tighten to 28-38 ft-lbs (38.0-51.6 Nm).

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

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 (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).

Vehicles with dual front brake calipers: repeat previous
two steps for other brake caliper.

See

Figure 2-93

. Remove cover screws (3), top cover (2)

and gasket from front brake master cylinder reservoir (1).

NOTES

•

See

Figure 2-94

. Do not use sight glass to determine

maximum fluid level. Sight glass should only be used as
a visual indicator that fluid level is low and needs attention.

•

Cover handlebar switches with a shop towel before adding
brake fluid to front master cylinder reservoir. Spilling brake
fluid on handlebar switches may render them inoperative.

•

Use only HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID
from a sealed container.

•

Do not overfill reservoir. Do not reuse old brake fluid.

See

Figure 2-94

. Add enough HARLEY-DAVIDSON D.O.T.

4 BRAKE FLUID to reservoir to bring fluid level even with
ridge cast into inside of reservoir, about 1/4 in. (6.35 mm)
below top edge

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)

Bleed brake system. See

1.8 BLEEDING HYDRAULIC

BRAKE SYSTEM

NOTE

On models with dual front brake calipers, make sure to perform
brake system bleeding procedure on both calipers.

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)

Verify proper operation of master cylinder relief port. With
motorcycle positioned so that master cylinder reservoir is
level, squeeze brake lever slowly with reservoir cover
removed. A slight spurt of fluid will break the surface if all
internal components are working properly.

See

Figure 2-94

. Add enough HARLEY-DAVIDSON D.O.T.

4 BRAKE FLUID to reservoir to bring fluid level even with
ridge cast into inside of reservoir, about 1/4 in. (6.35 mm)
below top edge.

10. Install gasket and cover on master cylinder. Tighten cover

screws to 9-17 in-lbs (1.0-2.0 Nm).

11. Tighten front axle and slider cap nuts if necessary.

12. Test brake system.

Turn ignition switch ON. Squeeze brake hand lever
to verify operation of the brake lamp.

Test ride the motorcycle. If the brakes feel spongy,
bleed the system again. See

1.8 BLEEDING

HYDRAULIC BRAKE SYSTEM

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2-58 2009 Sportster Service: Chassis

NOTE

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

sm01333

Banjo bolt

Washer (2)

Front brake line

Brake caliper

Caliper mounting bracket

Mounting bolt (2) (12 pt/10 mm)

Pad pin plug

Bleeder valve

Bleeder nipple cap

Figure 2-92. Front Caliper Assembly

sm01449

Front brake master cylinder and reservoir

Top cover

Cover screw (2)

Figure 2-93. Removing Master Cylinder Reservoir Cover

sm01244

Cast-in ridge

Sight glass

Figure 2-94. Filling Front Master Cylinder Reservoir

HOME

2009 Sportster Service: Chassis 2-59

2.12

FRONT BRAKE CALIPER: XR MODELS

REMOVAL

NOTE

If only replacing brake pads, do not remove front brake cal-
iper(s). For brake pad replacement only, see

1.10 BRAKE

PADS AND DISCS: XR MODELS

NOTE

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

NOTE

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

See

Figure 2-95

. Remove bleeder nipple cap from bleeder

valve (1) on front brake caliper.

See

Figure 2-96

. Install end of a length of 5/16 in. (7.9

mm) I.D. clear plastic tubing over caliper bleeder valve,
while placing free end in a suitable container. Open
bleeder valve about 1/2 turn. Pump brake hand lever
repeatedly to drain brake fluid. Close bleeder valve.

See

Figure 2-95

. Remove the banjo bolt (2) (metric) and

both washers (3) to detach front brake line from caliper.
Discard washers.

Remove both mounting bolts (4) (metric). Pull caliper
assembly rearward to remove from brake disc.

sm05098

Bleeder valve

Banjo bolt (metric)

Washer (2)

Mounting bolt (2) (metric)

Banjo fitting

Figure 2-95. Front Caliper Assembly: XR Models

sm01424

Figure 2-96. Bleeding Hydraulic System (typical; XL model

shown)

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2-60 2009 Sportster Service: Chassis

sm05107

Bleeder valve cap

Outer caliper housing

10.

Upper piston (large) (2)

Caliper mounting bolt (2)

11.

Bridge bolt (4)

Piston seal (large) (2)

12.

Piston dust seal (large) (2)

Pad pin (2)

13.

Pad set

Pad spring

14.

Crossover seal

Piston dust seal (small) (2)

15.

Piston seal (small) (2)

Inner caliper housing

16.

Bleeder valve

Lower piston (small) (2)

Figure 2-97. Front Brake Caliper Assembly

DISASSEMBLY

See

Figure 2-98

. Remove brake pad pins (1) and anti-

rattle spring (2).

Slide one brake pad out of caliper assembly. Do not
remove bleeder valve (3) at this time.

With one brake pad in the caliper, loosely install brake pad
pins (1) to hold brake pad in place.

NOTE

Be careful not to damage banjo bolt sealing surface or threads
of banjo bolt hole in brake caliper. It is recommended that you

HOME

2009 Sportster Service: Chassis 2-61

use an air nozzle with a rubber tip to perform the next step in
this procedure.

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)

See

Figure 2-98

. Gently apply low pressure compressed

air to banjo bolt hole (4) to force pistons from caliper bores.

Remove brake pad pins and brake pad.

Remove bridge bolts (5, 6) and separate caliper housings.

Remove pistons from each housing by hand. If necessary,
wiggle pistons gently to completely remove.

NOTE

Damaged piston bores will leak when reassembled. Do not
use metal objects to remove or install objects from piston bores.
Prevent damage to pistons, seals and bores by only using a
wooden toothpick when servicing calipers.

See

Figure 2-99

. Using a wooden toothpick (1), remove

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

See

Figure 2-98

. If necessary, remove bleeder valve (3).

sm05099

Pad pins (2) (metric)

Spring

Bleeder valve

Banjo bolt hole

Bridge bolt, long (2)

Bridge bolt, short (2)

Figure 2-98. Preparing Caliper for Piston Removal

sm05100

Wooden toothpick

Dust seal

Piston seal

Figure 2-99. Caliper Seals

CLEANING, INSPECTION AND REPAIR

Clean all rubber parts with HARLEY-DAVIDSON D.O.T.
4 BRAKE FLUID. Do not contaminate with mineral oil or
other solvents. Clean all metal parts with denatured
alcohol. 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 pistons for pitting, scratches or corrosion on
outside surfaces.

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

NOTE

The pad pins are manufactured with a relief near the center
of their length, where the pad spring touches. Do not use

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2-62 2009 Sportster Service: Chassis

this area as a measurement point to determine pad pin
wear.

Inspect pad pin for grooving and wear at the pad
contact points. Measure the pad pin diameter in an
unworn area, and then in an area of any grooving or
wear. If wear is more than 0.011 in. (0.28 mm),
replace pad pin.

Inspect pad spring for wear or cracks. If worn or
damaged, replace.

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

1.10 BRAKE PADS AND DISCS: XR MODELS

for specifications.

See

2.4 WHEELS

for brake disc replacement pro-

cedure.

ASSEMBLY

NOTE

Use ONLY KS62F assembly grease for lubrication. Use of
D.O.T. 4 brake fluid will result in increased brake lever 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 pistons.

All surfaces of piston seals and dust seals.

NOTES

•

Damaged piston bores will leak when reassembled. Do
not use metal objects to remove or install objects in piston
bores. Prevent damage to bores by only using a wooden
toothpick when servicing calipers.

•

Pistons and bores differ slightly in diameter; one large and
one small in each housing.

See

Figure 2-99

. Install a new piston seal (3) and a new

dust seal (2) into each piston bore.

See

Figure 2-100

.Carefully insert pistons (2, 3) by hand,

nose radius first, into caliper bores. If installation shows
resistance, remove piston(s) and check that seals are
properly installed and fully seated in grooves. Press pis-
tons completely into bores.

Install new crossover seal (1).

See

Figure 2-98

. Apply a drop of LOCTITE 569 Sealant

to the threads of the bridge bolts (5, 6). Assemble caliper
housings and secure with bridge bolts. Ensure the bridge
bolts are in the correct locations based on length. Tighten
bridge bolts to 12-18 ft-lbs (16.9-24.5 Nm).

See

Figure 2-101

. Install brake pads and pad spring.

Ensure the spring is oriented as shown with the arrow and

word "UP" (2) facing the banjo bolt hole (1). Secure with
pad pins (3).

Tighten pad pins to 11-14 ft-lbs (14.7-19.6 Nm).

Install bleeder valve on caliper housing if removed. Tighten
bleeder valve to 35-61 in-lbs (4.0-6.9 Nm).

sm05102

Crossover seal

Large piston (2)

Small piston (2)

Figure 2-100. Caliper Housings and Pistons

sm05101

Banjo bolt hole

Arrow and word "UP"

Pad pins (2)

Figure 2-101. Front Caliper Pad Spring Orientation

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2009 Sportster Service: Chassis 2-63

INSTALLATION

NOTE

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

Align calipers to brake discs.

Tighten axle nut to 60-65 ft-lbs (81-88 Nm).

Loosen axle pinch screw nut.

Position right fork leg against bearing spacer. Tighten
axle pinch screw to 41-48 in-lbs (55.6-65.1 Nm).

See

Figure 2-102

. Place brake caliper over brake disc with

bleeder valve (1) facing upwards. Install mounting bolts
(4) and tighten to 28-38 ft-lbs (38.0-51.6 Nm).

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

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 banjo fitting (5). Insert banjo bolt (2) through washers
and fitting. Tighten banjo bolt to 20-25 ft-lbs (27.1-33.9
Nm).

Fill and bleed brake system. See

1.8 BLEEDING

HYDRAULIC BRAKE SYSTEM

NOTE

Make sure to perform brake system bleeding procedure on
both calipers.

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)

Install gasket and cover on master cylinder. Tighten cover
screws to 9-17 in-lbs (1.0-2.0 Nm).

Test brake system.

Turn ignition switch ON. Squeeze brake hand lever
to verify operation of the brake lamp.

Test ride the motorcycle. If the brakes feel spongy,
bleed the system again. See

1.8 BLEEDING

HYDRAULIC BRAKE SYSTEM

NOTE

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

sm05098

Bleeder valve

Banjo bolt (metric)

Washer (2)

Mounting bolt (2) (metric)

Banjo fitting

Figure 2-102. Front Caliper Assembly: XR Models

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2-64 2009 Sportster Service: Chassis

2.13

REAR BRAKE MASTER CYLINDER: XL MODELS

GENERAL

The rear brake master cylinder is mounted transverse to the
centerline of the vehicle, beneath the rear fork pivot shaft
assembly.

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

NOTE

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

INSPECTION

Check the level of fluid in the rear brake reservoir. If it is
low, refill and bleed brake system. See

1.8 BLEEDING

HYDRAULIC BRAKE SYSTEM

Check for fluid leaks in the brake line, around banjo fittings
or rear brake caliper piston or bleeder valve. Repair and
bleed brake system.

For brake line replacement procedure, see

2.18 BRAKE LINES

To repair rear brake caliper, see procedure in

2.16 REAR BRAKE CALIPER: XL MODELS

See

1.8 BLEEDING HYDRAULIC BRAKE SYSTEM

for hydraulic brake system bleeding procedure.

Check rear brake friction pads and disc for excessive wear
or damage. Replace worn or damaged items.

See

1.9 BRAKE PADS AND DISCS: XL MODELS

for

specifications.

See

1.9 BRAKE PADS AND DISCS: XL MODELS,

Brake Pad Replacement: Rear

for brake pad

replacement procedure.

See

2.4 WHEELS

for brake disc replacement pro-

cedure.

Check mechanical brake linkage from brake pedal to
master cylinder for damage. Repair or replace worn or
damaged items.

Models equipped with mid-mount foot controls:
see

2.40 RIDER FOOT CONTROLS: XL MODELS

EQUIPPED WITH MID-MOUNT CONTROLS

Models equipped with forward foot controls: see

2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS

Eliminate any air in the hydraulic brake assembly by
bleeding the system. See

1.8 BLEEDING HYDRAULIC

BRAKE SYSTEM

If none of these conditions exist but the rear brake system does
not operate properly, the rear master cylinder is most likely
defective and must be repaired or replaced.

REMOVAL

See

Figure 2-103

. Drain rear brake master cylinder

reservoir (1) and remove hose clamp (4) and feed hose
(3) from master cylinder feed hose port fitting (5). See

2.15 REAR BRAKE MASTER CYLINDER RESERVOIR

Discard hose clamp.

Remove bleeder nipple cap (21) from bleeder valve (22)
on rear brake caliper (20). Install end of a length of 5/16
in. (7.9 mm) I.D. clear plastic tubing over caliper bleeder
valve, while placing free end in a suitable container.

Open bleeder valve about 1/2-turn. Pump brake pedal to
drain brake fluid. Close bleeder valve but do not tighten.

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)

NOTE

Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.

Remove retaining ring (11) from clevis pin (9). Remove
clevis pin and disengage master cylinder yoke (10) from
bell crank (12). Discard retaining ring.

NOTE

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

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2009 Sportster Service: Chassis 2-65

Remove banjo bolt (18) and washers (16) from master
cylinder (6). Lift banjo fitting away from master cylinder.
Discard washers.

Remove two screws (7) and two washers (8) securing rear
master cylinder to master cylinder mounting bracket (15)
and remove rear master cylinder.

If it is necessary to remove master cylinder mounting
bracket:

Remove retaining ring (14) and clevis pin (13). Dis-
connect bell crank (12) from mounting bracket.

Remove two screws (23).

Remove screw (24) and mounting bracket.

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2-66 2009 Sportster Service: Chassis

sm01807

13.

Clevis pin

Rear brake master cylinder reservoir

14.

B-clamp

Retaining ring

15.

Master cylinder mounting bracket

Master cylinder feed hose

16.

Hose clamp

Washer (2)

17.

Banjo fitting

Feed hose port fitting

18.

Rear brake master cylinder

Banjo bolt

19.

Rear brake line including stoplight switch

Screw (2)

20.

Washer (2)

Rear brake caliper

21.

Bleeder nipple cap

Clevis pin

10.

22.

Yoke

Bleeder valve

23.

11.

Screw (2)

Retaining ring

12.

24.

Bell crank

Screw

Figure 2-103. Rear Brake Master Cylinder and Reservoir

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2009 Sportster Service: Chassis 2-67

DISASSEMBLY

NOTE

•

Do not disassemble the rear master cylinder unless prob-
lems are being experienced. Discard all seals during the
disassembly procedure. Install a complete rebuild kit when
the unit is reassembled.

•

See

Figure 2-105

. Clamp rear brake master cylinder (19)

in a vise by its mounting bosses (18) only. Use brass or
aluminum jaw covers or other protective device on vise
jaws to prevent damage to master cylinder.

See

Figure 2-105

. Clamp rear brake master cylinder (19)

in a vise with yoke (3) pointing up.

Remove external boot (5). Remove spring pin (12) from
end of push rod (13). Discard spring pin.

NOTE

See

Figure 2-104

. Grip yoke by the edges with an adjustable

wrench. Do not grip yoke by the flats or the yoke may become
deformed.

See

Figure 2-104

. Hold yoke with an adjustable wrench.

Using an open-end wrench, loosen shoulder nut. Remove
yoke.

Wear safety glasses or goggles when removing or
installing spring. Spring tension can cause spring,
attached components and/or hand tools to fly out which
could result in death or serious injury. (00477c)

See

Figure 2-105

. Press down on spring retainer (6) to

compress external return spring (7). While spring is com-
pressed, remove shoulder nut from push rod. Carefully
release pressure on external return spring. Remove spring
retainer and external return spring.

Remove and discard inner boot (8).

NOTE

Do not remove boot collar nut (9) and push rod retainer (11)
from push rod.

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)

NOTE

Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.

Thread shoulder nut back onto push rod several turns, to
protect push rod threads. Press down on push rod to
compress piston spring (17). Remove retaining ring (10),
push rod with boot collar nut (9) and push rod retainer
(11), piston (15) with secondary cup (14), primary cup (16)
and piston spring. Discard retaining ring, piston with sec-
ondary cup, primary cup and piston spring.

Remove dust cover (23), retaining ring (22), feed port fitting
(21) and o-ring (20). Discard retaining ring and o-ring.

sm01808

Figure 2-104. Tightening Yoke (Top: Incorrect, Bottom:

Correct)

HOME

2-68 2009 Sportster Service: Chassis

sm03351

14.

Secondary cup*

Retaining ring

15.

Clevis pin

Piston*

16.

Primary cup*

Yoke

17.

Shoulder nut

Piston spring*

18.

Mounting boss (2)

External boot

19.

Spring retainer

Master cylinder body

20.

O-ring

External return spring

21.

Inner boot*

Feed port fitting

22.

Retaining ring

Boot collar nut

10.

23.

Retaining ring*

Dust cover

24.

11.

G40M brake grease*

Push rod retainer

12.

25.

Spring pin*

CCI #20 brake grease*

13. Push rod

Figure 2-105. Rear Brake Master Cylinder (*Provided in Service Parts Kit)

CLEANING, INSPECTION AND REPAIR

See

Figure 2-105

. Thoroughly clean master cylinder body

(19) and all brake system components. Blow out drilled

HOME

2009 Sportster Service: Chassis 2-69

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